Robotically-controlled motorized surgical instrument with an end effector

ABSTRACT

A surgical tool configured for operation in connection with a robotic system. The surgical tool includes a shaft and an end effector extending distally from the shaft. The end effector comprises a first jaw member and a second jaw member movable relative to the first jaw member from a closed position to an open position in response to at least one axial motion. In addition, the surgical tool includes a motor configured to generate at least one rotational motion and a motion conversion assembly operably coupled to the motor and the second jaw member, wherein the motion conversion assembly is configured to convert the at least one rotational motion to the at least one axial motion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application claiming priority under35 U.S.C. § 120 to U.S. patent application Ser. No. 16/146,335, filedSep. 28, 2018, entitled ROBOTICALLY-CONTROLLED MOTORIZED SURGICALINSTRUMENT WITH AN END EFFECTOR, which issued on Sep. 8, 2020 as U.S.Pat. No. 10,765,425, which is a continuation application claimingpriority under 35 U.S.C. § 120 to U.S. patent application Ser. No.15/274,826, filed Sep. 23, 2016, entitled ROBOTICALLY-CONTROLLEDMOTORIZED SURGICAL INSTRUMENT WITH AN END EFFECTOR, which issued on Nov.20, 2018 as U.S. Pat. No. 10,130,361, which is a continuationapplication claiming priority under 35 U.S.C. § 120 to U.S. patentapplication Ser. No. 13/792,263, filed Mar. 11, 2013, entitledROBOTICALLY-CONTROLLED MOTORIZED SURGICAL INSTRUMENT WITH AN ENDEFFECTOR, which issued on May 23, 2017 as U.S. Pat. No. 9,655,614, whichis a continuation application claiming priority under 35 U.S.C. § 120 toU.S. patent application Ser. No. 13/118,253, filed May 27, 2011,entitled ROBOTICALLY-CONTROLLED MOTORIZED SURGICAL INSTRUMENT, whichissued on Jul. 12, 2016 as U.S. Pat. No. 9,386,983, is acontinuation-in-part application claiming priority under 35 U.S.C. § 120to U.S. patent application Ser. No. 12/235,972, filed Sep. 23, 2008,entitled MOTORIZED SURGICAL INSTRUMENT, which issued Jun. 9, 2015 asU.S. Pat. No. 9,050,083, the entire disclosures of which are herebyincorporated by reference herein.

BACKGROUND

Surgical staplers have been used in the prior art to simultaneously makea longitudinal incision in tissue and apply lines of staples on opposingsides of the incision. Such instruments commonly include a pair ofcooperating jaw members that, if the instrument is intended forendoscopic or laparoscopic applications, are capable of passing througha cannula passageway. One of the jaw members receives a staple cartridgehaving at least two laterally spaced rows of staples. The other jawmember defines an anvil having staple-forming pockets aligned with therows of staples in the cartridge. Such instruments typically include aplurality of reciprocating wedges that, when driven distally, passthrough openings in the staple cartridge and engage drivers supportingthe staples to effect the firing of the staples toward the anvil.

An example of a surgical stapler suitable for endoscopic applications isdescribed in published U.S. Patent Application Publication No.2004/0232196, entitled SURGICAL STAPLING INSTRUMENT HAVING SEPARATEDISTINCT CLOSING AND FIRING SYSTEMS, now U.S. Pat. No. 7,000,818, thedisclosure of which is herein incorporated by reference. In use, aclinician is able to close the jaw members of the stapler upon tissue toposition the tissue prior to firing. Once the clinician has determinedthat the jaw members are properly gripping tissue, the clinician canfire the surgical stapler, thereby severing and stapling the tissue. Thesimultaneous severing and stapling steps avoid complications that mayarise when performing such actions sequentially with different surgicaltools that respectively only sever or staple.

Motor-powered surgical cutting and fastening instruments, where a motorpowers the cutting instrument, are also known in the prior art, such asdescribed in published U.S. Patent Application Publication No.2007/0175962, entitled MOTOR-DRIVEN SURGICAL CUTTING AND FASTENINGINSTRUMENT WITH TACTILE POSITION FEEDBACK, now U.S. Pat. No. 7,422,139,which is incorporated herein by reference. In this reference, a batteryin the handle is used to electrically power the motor.

FIGURES

Various embodiments of the present invention are described herein by wayof example in conjunction with the following figures, wherein:

FIGS. 1 and 2 are perspective views of a surgical cutting and fasteninginstrument according to various embodiments of the present invention;

FIGS. 3-5 are exploded views of an end effector and shaft of theinstrument according to various embodiments of the present invention;

FIG. 6 is a side view of the end effector according to variousembodiments of the present invention;

FIG. 7 is an exploded view of the handle of the instrument according tovarious embodiments of the present invention;

FIGS. 8 and 9 are partial perspective views of the handle according tovarious embodiments of the present invention;

FIG. 10 is a side view of the handle according to various embodiments ofthe present invention;

FIG. 11 is a schematic diagram of a circuit used in the instrumentaccording to various embodiments of the present invention;

FIGS. 12-14 and 17 are schematic diagrams of circuits used to power themotor of the instrument according to various embodiments of the presentinvention;

FIG. 15 is a block diagram illustrating a charge management circuitaccording to various embodiments of the present invention;

FIG. 16 is a block diagram illustrating a charger base according tovarious embodiments of the present invention;

FIG. 18 illustrates a typical power curve of a battery;

FIGS. 19 and 20 are schematic diagrams of circuits used in theinstrument according to various embodiments of the present invention;

FIGS. 21 and 23 are diagrams of instruments according to variousembodiments of the present invention;

FIGS. 22 and 24 are diagrams of battery packs according to variousembodiments of the present invention;

FIG. 25 is a perspective view of one robotic controller embodiment;

FIG. 26 is a perspective view of one robotic surgical armcart/manipulator of a robotic system operably supporting a plurality ofsurgical tool embodiments of the present invention;

FIG. 27 is a side view of the robotic surgical arm cart/manipulatordepicted in FIG. 26;

FIG. 28 is a perspective view of an exemplary cart structure withpositioning linkages for operably supporting robotic manipulators thatmay be used with various surgical tool embodiments of the presentinvention;

FIG. 29 is a perspective view of a surgical tool embodiment of thepresent invention;

FIG. 30 is an exploded assembly view of an adapter and tool holderarrangement for attaching various surgical tool embodiments to a roboticsystem;

FIG. 31 is a side view of the adapter shown in FIG. 30;

FIG. 32 is a bottom view of the adapter shown in FIG. 30;

FIG. 33 is a top view of the adapter of FIGS. 30 and 31;

FIG. 34 is a partial bottom perspective view of the surgical toolembodiment of FIG. 29;

FIG. 35 is a partial exploded view of a portion of an articulatablesurgical end effector embodiment of the present invention;

FIG. 36 is a perspective view of the surgical tool embodiment of FIG. 34with the tool mounting housing removed;

FIG. 37 is a rear perspective view of the surgical tool embodiment ofFIG. 34 with the tool mounting housing removed;

FIG. 38 is a front perspective view of the surgical tool embodiment ofFIG. 34 with the tool mounting housing removed;

FIG. 39 is a partial exploded perspective view of the surgical toolembodiment of FIG. 38;

FIG. 40 is a partial cross-sectional side view of the surgical toolembodiment of FIG. 34;

FIG. 41 is an enlarged cross-sectional view of a portion of the surgicaltool depicted in FIG. 37;

FIG. 42 is an exploded perspective view of a portion of the toolmounting portion of the surgical tool embodiment depicted in FIG. 34;

FIG. 43 is an enlarged exploded perspective view of a portion of thetool mounting portion of FIG. 42;

FIG. 44 is a partial cross-sectional view of a portion of the elongatedshaft assembly of the surgical tool of FIG. 34;

FIG. 45 is a side view of a half portion of a closure nut embodiment ofa surgical tool embodiment of the present invention;

FIG. 46 is a perspective view of another surgical tool embodiment of thepresent invention;

FIG. 47 is a cross-sectional side view of a portion of the surgical endeffector and elongated shaft assembly of the surgical tool embodiment ofFIG. 46 with the anvil in the open position and the closure clutchassembly in a neutral position;

FIG. 48 is another cross-sectional side view of the surgical endeffector and elongated shaft assembly shown in FIG. 47 with the clutchassembly engaged in a closure position;

FIG. 49 is another cross-sectional side view of the surgical endeffector and elongated shaft assembly shown in FIG. 47 with the clutchassembly engaged in a firing position;

FIG. 50 is a top view of a portion of a tool mounting portion embodimentof the present invention;

FIG. 51 is a perspective view of another surgical tool embodiment of thepresent invention;

FIG. 52 is a cross-sectional side view of a portion of the surgical endeffector and elongated shaft assembly of the surgical tool embodiment ofFIG. 51 with the anvil in the open position;

FIG. 53 is another cross-sectional side view of a portion of thesurgical end effector and elongated shaft assembly of the surgical toolembodiment of FIG. 51 with the anvil in the closed position;

FIG. 54 is a perspective view of a closure drive nut and portion of aknife bar embodiment of the present invention;

FIG. 55 is a top view of another tool mounting portion embodiment of thepresent invention;

FIG. 56 is a perspective view of another surgical tool embodiment of thepresent invention;

FIG. 57 is a cross-sectional side view of a portion of the surgical endeffector and elongated shaft assembly of the surgical tool embodiment ofFIG. 56 with the anvil in the open position;

FIG. 58 is another cross-sectional side view of a portion of thesurgical end effector and elongated shaft assembly of the surgical toolembodiment of FIG. 57 with the anvil in the closed position;

FIG. 59 is a cross-sectional view of a mounting collar embodiment of asurgical tool embodiment of the present invention showing the knife barand distal end portion of the closure drive shaft;

FIG. 60 is a cross-sectional view of the mounting collar embodiment ofFIG. 59;

FIG. 61 is a top view of another tool mounting portion embodiment ofanother surgical tool embodiment of the present invention;

FIG. 61A is an exploded perspective view of a portion of a geararrangement of another surgical tool embodiment of the presentinvention;

FIG. 61B is a cross-sectional perspective view of the gear arrangementshown in FIG. 61A;

FIG. 62 is a cross-sectional side view of a portion of a surgical endeffector and elongated shaft assembly of another surgical toolembodiment of the present invention employing a pressure sensorarrangement with the anvil in the open position;

FIG. 63 is another cross-sectional side view of a portion of thesurgical end effector and elongated shaft assembly of the surgical toolembodiment of FIG. 62 with the anvil in the closed position;

FIG. 64 is a side view of a portion of another surgical tool embodimentof the present invention in relation to a tool holder portion of arobotic system with some of the components thereof shown incross-section;

FIG. 65 is a side view of a portion of another surgical tool embodimentof the present invention in relation to a tool holder portion of arobotic system with some of the components thereof shown incross-section;

FIG. 66 is a side view of a portion of another surgical tool embodimentof the present invention with some of the components thereof shown incross-section;

FIG. 67 is a side view of a portion of another surgical end effectorembodiment of a portion of a surgical tool embodiment of the presentinvention with some components thereof shown in cross-section;

FIG. 68 is a side view of a portion of another surgical end effectorembodiment of a portion of a surgical tool embodiment of the presentinvention with some components thereof shown in cross-section;

FIG. 69 is a side view of a portion of another surgical end effectorembodiment of a portion of a surgical tool embodiment of the presentinvention with some components thereof shown in cross-section;

FIG. 70 is an enlarged cross-sectional view of a portion of the endeffector of FIG. 69;

FIG. 71 is another cross-sectional view of a portion of the end effectorof FIGS. 69 and 70;

FIG. 72 is a cross-sectional side view of a portion of a surgical endeffector and elongated shaft assembly of another surgical toolembodiment of the present invention with the anvil in the open position;

FIG. 73 is an enlarged cross-sectional side view of a portion of thesurgical end effector and elongated shaft assembly of the surgical toolembodiment of FIG. 72;

FIG. 74 is another cross-sectional side view of a portion of thesurgical end effector and elongated shaft assembly of FIGS. 72 and 73with the anvil thereof in the closed position;

FIG. 75 is an enlarged cross-sectional side view of a portion of thesurgical end effector and elongated shaft assembly of the surgical toolembodiment of FIGS. 72-74;

FIG. 76 is a top view of a tool mounting portion embodiment of asurgical tool embodiment of the present invention;

FIG. 77 is a perspective assembly view of another surgical toolembodiment of the present invention;

FIG. 78 is a front perspective view of a disposable loading unitarrangement that may be employed with various surgical tool embodimentsof the present invention;

FIG. 79 is a rear perspective view of the disposable loading unit ofFIG. 78;

FIG. 80 is a bottom perspective view of the disposable loading unit ofFIGS. 78 and 79;

FIG. 81 is a bottom perspective view of another disposable loading unitembodiment that may be employed with various surgical tool embodimentsof the present invention;

FIG. 82 is an exploded perspective view of a mounting portion of adisposable loading unit depicted in FIGS. 78-80;

FIG. 83 is a perspective view of a portion of a disposable loading unitand an elongated shaft assembly embodiment of a surgical tool embodimentof the present invention with the disposable loading unit in a firstposition;

FIG. 84 is another perspective view of a portion of the disposableloading unit and elongated shaft assembly of FIG. 83 with the disposableloading unit in a second position;

FIG. 85 is a cross-sectional view of a portion of the disposable loadingunit and elongated shaft assembly embodiment depicted in FIGS. 83 and84;

FIG. 86 is another cross-sectional view of the disposable loading unitand elongated shaft assembly embodiment depicted in FIGS. 83-85;

FIG. 87 is a partial exploded perspective view of a portion of anotherdisposable loading unit embodiment and an elongated shaft assemblyembodiment of a surgical tool embodiment of the present invention;

FIG. 88 is a partial exploded perspective view of a portion of anotherdisposable loading unit embodiment and an elongated shaft assemblyembodiment of a surgical tool embodiment of the present invention;

FIG. 89 is another partial exploded perspective view of the disposableloading unit embodiment and an elongated shaft assembly embodiment ofFIG. 88;

FIG. 90 is a top view of another tool mounting portion embodiment of asurgical tool embodiment of the present invention;

FIG. 91 is a side view of another surgical tool embodiment of thepresent invention with some of the components thereof shown incross-section and in relation to a robotic tool holder of a roboticsystem;

FIG. 92 is an exploded assembly view of a surgical end effectorembodiment that may be used in connection with various surgical toolembodiments of the present invention;

FIG. 93 is a side view of a portion of a cable-driven system for drivinga cutting instrument employed in various surgical end effectorembodiments of the present invention;

FIG. 94 is a top view of the cable-driven system and cutting instrumentof FIG. 93;

FIG. 95 is a top view of a cable drive transmission embodiment of thepresent invention in a closure position;

FIG. 96 is another top view of the cable drive transmission embodimentof FIG. 95 in a neutral position;

FIG. 97 is another top view of the cable drive transmission embodimentof FIGS. 95 and 96 in a firing position;

FIG. 98 is a perspective view of the cable drive transmission embodimentin the position depicted in FIG. 95;

FIG. 99 is a perspective view of the cable drive transmission embodimentin the position depicted in FIG. 96;

FIG. 100 is a perspective view of the cable drive transmissionembodiment in the position depicted in FIG. 97;

FIG. 101 is a perspective view of another surgical tool embodiment ofthe present invention;

FIG. 102 is a side view of a portion of another cable-driven systemembodiment for driving a cutting instrument employed in various surgicalend effector embodiments of the present invention;

FIG. 103 is a top view of the cable-driven system embodiment of FIG.102;

FIG. 104 is a top view of a tool mounting portion embodiment of anothersurgical tool embodiment of the present invention;

FIG. 105 is a top cross-sectional view of another surgical toolembodiment of the present invention;

FIG. 106 is a cross-sectional view of a portion of a surgical endeffector embodiment of a surgical tool embodiment of the presentinvention;

FIG. 107 is a cross-sectional end view of the surgical end effector ofFIG. 106 taken along line 107-107 in FIG. 106;

FIG. 108 is a perspective view of the surgical end effector of FIGS. 106and 107 with portions thereof shown in cross-section;

FIG. 109 is a side view of a portion of the surgical end effector ofFIGS. 106-108;

FIG. 110 is a perspective view of a sled assembly embodiment of varioussurgical tool embodiments of the present invention;

FIG. 111 is a cross-sectional view of the sled assembly embodiment ofFIG. 110 and a portion of the elongated channel of FIG. 109;

FIGS. 112-117 diagrammatically depict the sequential firing of staplesin a surgical tool embodiment of the present invention;

FIG. 118 is a partial perspective view of a portion of a surgical endeffector embodiment of the present invention;

FIG. 119 is a partial cross-sectional perspective view of a portion of asurgical end effector embodiment of a surgical tool embodiment of thepresent invention;

FIG. 120 is another partial cross-sectional perspective view of thesurgical end effector embodiment of FIG. 119 with a sled assemblyaxially advancing therethrough;

FIG. 121 is a perspective view of another sled assembly embodiment ofanother surgical tool embodiment of the present invention;

FIG. 122 is a partial top view of a portion of the surgical end effectorembodiment depicted in FIGS. 119 and 120 with the sled assembly axiallyadvancing therethrough;

FIG. 123 is another partial top view of the surgical end effectorembodiment of FIG. 122 with the top surface of the surgical staplecartridge omitted for clarity;

FIG. 124 is a partial cross-sectional side view of a rotary driverembodiment and staple pusher embodiment of the surgical end effectordepicted in FIGS. 119 and 120;

FIG. 125 is a perspective view of an automated reloading systemembodiment of the present invention with a surgical end effector inextractive engagement with the extraction system thereof;

FIG. 126 is another perspective view of the automated reloading systemembodiment depicted in FIG. 125;

FIG. 127 is a cross-sectional elevational view of the automatedreloading system embodiment depicted in FIGS. 125 and 126;

FIG. 128 is another cross-sectional elevational view of the automatedreloading system embodiment depicted in FIGS. 125-127 with theextraction system thereof removing a spent surgical staple cartridgefrom the surgical end effector;

FIG. 129 is another cross-sectional elevational view of the automatedreloading system embodiment depicted in FIGS. 125-127 illustrating theloading of a new surgical staple cartridge into a surgical end effector;

FIG. 130 is a perspective view of another automated reloading systemembodiment of the present invention with some components shown incross-section;

FIG. 131 is an exploded perspective view of a portion of the automatedreloading system embodiment of FIG. 130;

FIG. 132 is another exploded perspective view of the portion of theautomated reloading system embodiment depicted in FIG. 131;

FIG. 133 is a cross-sectional elevational view of the automatedreloading system embodiment of FIGS. 130-132;

FIG. 134 is a cross-sectional view of an orientation tube embodimentsupporting a disposable loading unit therein;

FIG. 135 is a perspective view of another surgical tool embodiment ofthe present invention;

FIG. 136 is a partial perspective view of an articulation jointembodiment of a surgical tool embodiment of the present invention;

FIG. 137 is a perspective view of a closure tube embodiment of asurgical tool embodiment of the present invention;

FIG. 138 is a perspective view of the closure tube embodiment of FIG.137 assembled on the articulation joint embodiment of FIG. 136;

FIG. 139 is a top view of a portion of a tool mounting portionembodiment of a surgical tool embodiment of the present invention;

FIG. 140 is a perspective view of an articulation drive assemblyembodiment employed in the tool mounting portion embodiment of FIG. 139;

FIG. 141 is a perspective view of another surgical tool embodiment ofthe present invention; and

FIG. 142 is a perspective view of another surgical tool embodiment ofthe present invention.

DETAILED DESCRIPTION

Applicant of the present application also owns the following patentapplications filed on May 27, 2011, and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 13/118,259, entitled SURGICALINSTRUMENT WITH WIRELESS COMMUNICATION BETWEEN A CONTROL UNIT OF AROBOTIC SYSTEM AND REMOTE SENSOR, now U.S. Pat. No. 8,684,253;

U.S. patent application Ser. No. 13/118,210, entitledROBOTICALLY-CONTROLLED DISPOSABLE MOTOR DRIVEN LOADING UNIT, now U.S.Pat. No. 8,752,749;

U.S. patent application Ser. No. 13/118,194, entitledROBOTICALLY-CONTROLLED ENDOSCOPIC ACCESSORY CHANNEL, now U.S. Pat. No.8,992,422;

U.S. patent application Ser. No. 13/118,278, entitledROBOTICALLY-CONTROLLED SURGICAL STAPLING DEVICES THAT PRODUCE FORMEDSTAPLES HAVING DIFFERENT LENGTHS, now U.S. Pat. No. 9,237,891;

U.S. patent application Ser. No. 13/118,190, entitledROBOTICALLY-CONTROLLED MOTORIZED CUTTING AND FASTENING INSTRUMENT, nowU.S. Pat. No. 9,179,912;

U.S. patent application Ser. No. 13/118,223, entitledROBOTICALLY-CONTROLLED SHAFT BASED ROTARY DRIVE SYSTEMS FOR SURGICALINSTRUMENTS, now U.S. Pat. No. 8,931,682;

U.S. patent application Ser. No. 13/118,263, entitledROBOTICALLY-CONTROLLED SURGICAL INSTRUMENT HAVING RECORDINGCAPABILITIES, now U.S. Patent Application Publication No. 2011/0295295;

U.S. patent application Ser. No. 13/118,272, entitledROBOTICALLY-CONTROLLED SURGICAL INSTRUMENT WITH FORCE FEEDBACKCAPABILITIES, now U.S. Patent Application Publication No. 2011/0290856;

U.S. Patent application Ser. No. 13/118,246, entitled ROBOTICALLY-DRIVENSURGICAL INSTRUMENT WITH E-BEAM DRIVER, now U.S. Pat. No. 9,060,770; and

U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLINGINSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat.No. 9,072,535.

Certain exemplary embodiments will now be described to provide anoverall understanding of the principles of the structure, function,manufacture, and use of the devices and methods disclosed herein. One ormore examples of these embodiments are illustrated in the accompanyingdrawings. Those of ordinary skill in the art will understand that thedevices and methods specifically described herein and illustrated in theaccompanying drawings are non-limiting exemplary embodiments and thatthe scope of the various embodiments of the present invention is definedsolely by the claims. The features illustrated or described inconnection with one exemplary embodiment may be combined with thefeatures of other embodiments. Such modifications and variations areintended to be included within the scope of the present invention.

Uses of the phrases “in various embodiments,” “in some embodiments,” “inone embodiment”, or “in an embodiment”, or the like, throughout thespecification are not necessarily all referring to the same embodiment.Furthermore, the particular features, structures, or characteristics ofone or more embodiments may be combined in any suitable manner in one ormore other embodiments. Such modifications and variations are intendedto be included within the scope of the present invention.

FIGS. 1 and 2 depict a surgical cutting and fastening instrument 10according to various embodiments of the present invention. Theillustrated embodiment is an endoscopic instrument and, in general, theembodiments of the instrument 10 described herein are endoscopicsurgical cutting and fastening instruments. It should be noted, however,that according to other embodiments of the present invention, theinstrument may be a non-endoscopic surgical cutting and fasteninginstrument, such as a laparoscopic instrument.

The surgical instrument 10 depicted in FIGS. 1 and 2 comprises a handle6, a shaft 8, and an articulating end effector 12 pivotally connected tothe shaft 8 at an articulation pivot 14. An articulation control 16 maybe provided adjacent to the handle 6 to effect rotation of the endeffector 12 about the articulation pivot 14. In the illustratedembodiment, the end effector 12 is configured to act as an endocutterfor clamping, severing and stapling tissue, although, in otherembodiments, different types of end effectors may be used, such as endeffectors for other types of surgical devices, such as graspers,cutters, staplers, clip appliers, access devices, drug/gene therapydevices, ultrasound, RF or laser devices, etc. More details regarding RFdevices may be found in the '312 Patent.

The handle 6 of the instrument 10 may include a closure trigger 18 and afiring trigger 20 for actuating the end effector 12. It will beappreciated that instruments having end effectors directed to differentsurgical tasks may have different numbers or types of triggers or othersuitable controls for operating the end effector 12. The end effector 12is shown separated from the handle 6 by a preferably elongate shaft 8.In one embodiment, a clinician or operator of the instrument 10 mayarticulate the end effector 12 relative to the shaft 8 by utilizing thearticulation control 16, as described in more detail in published U.S.Patent Application Publication No. 2007/0158385, entitled SURGICALINSTRUMENT HAVING AN ARTICULATING END EFFECTOR, by Geoffrey C. Hueil etal., now U.S. Pat. No. 7,670,334, which is incorporated herein byreference.

The end effector 12 includes in this example, among other things, astaple channel 22 and a pivotally translatable clamping member, such asan anvil 24, which are maintained at a spacing that assures effectivestapling and severing of tissue clamped in the end effector 12. Thehandle 6 includes a pistol grip 26 towards which a closure trigger 18 ispivotally drawn by the clinician to cause clamping or closing of theanvil 24 toward the staple channel 22 of the end effector 12 to therebyclamp tissue positioned between the anvil 24 and channel 22. The firingtrigger 20 is farther outboard of the closure trigger 18. Once theclosure trigger 18 is locked in the closure position as furtherdescribed below, the firing trigger 20 may rotate slightly toward thepistol grip 26 so that it can be reached by the operator using one hand.Then the operator may pivotally draw the firing trigger 20 toward thepistol grip 12 to cause the stapling and severing of clamped tissue inthe end effector 12. In other embodiments, different types of clampingmembers besides the anvil 24 could be used, such as, for example, anopposing jaw, etc.

It will be appreciated that the terms “proximal” and “distal” are usedherein with reference to a clinician gripping the handle 6 of aninstrument 10. Thus, the end effector 12 is distal with respect to themore proximal handle 6. It will be further appreciated that, forconvenience and clarity, spatial terms such as “vertical” and“horizontal” are used herein with respect to the drawings. However,surgical instruments are used in many orientations and positions, andthese terms are not intended to be limiting and absolute.

The closure trigger 18 may be actuated first. Once the clinician issatisfied with the positioning of the end effector 12, the clinician maydraw back the closure trigger 18 to its fully closed, locked positionproximate to the pistol grip 26. The firing trigger 20 may then beactuated. The firing trigger 20 returns to the open position (shown inFIGS. 1 and 2) when the clinician removes pressure, as described morefully below. A release button on the handle 6, when depressed mayrelease the locked closure trigger 18. The release button may beimplemented in various forms such as, for example, as a slide releasebutton 160 shown in FIG. 7 or any of the mechanisms described inpublished U.S. Patent Application Publication No. 2007/0175955, which isincorporated herein by reference.

FIG. 3 is an exploded view of the end effector 12 according to variousembodiments. As shown in the illustrated embodiment, the end effector 12may include, in addition to the previously mentioned channel 22 andanvil 24, a cutting instrument 32, a sled 33, a staple cartridge 34 thatis removably seated in the channel 22, and a helical screw shaft 36. Thecutting instrument 32 may be, for example, a knife. The anvil 24 may bepivotably opened and closed at a pivot point 25 connected to theproximate end of the channel 22. The anvil 24 may also include a tab 27at its proximate end that is inserted into a component of the mechanicalclosure system (described further below) to open and close the anvil 24.When the closure trigger 18 is actuated, that is, drawn in by a user ofthe instrument 10, the anvil 24 may pivot about the pivot point 25 intothe clamped or closed position. If clamping of the end effector 12 issatisfactory, the operator may actuate the firing trigger 20, which, asexplained in more detail below, causes the knife 32 and sled 33 totravel longitudinally along the channel 22, thereby cutting tissueclamped within the end effector 12. The movement of the sled 33 alongthe channel 22 causes the staples of the staple cartridge 34 to bedriven through the severed tissue and against the closed anvil 24, whichturns the staples to fasten the severed tissue. In various embodiments,the sled 33 may be an integral component of the cartridge 34. U.S. Pat.No. 6,978,921, entitled SURGICAL STAPLING INSTRUMENT INCORPORATING ANE-BEAM FIRING MECHANISM, which is incorporated herein by reference,provides more details about such two-stroke cutting and fasteninginstruments. The sled 33 may be part of the cartridge 34, such that whenthe knife 32 retracts following the cutting operation, the sled 33 doesnot retract.

It should be noted that although the embodiments of the instrument 10described herein employ an end effector 12 that staples the severedtissue, in other embodiments different techniques for fastening orsealing the severed tissue may be used. For example, end effectors thatuse RF energy or adhesives to fasten the severed tissue may also beused. U.S. Pat. No. 5,709,680, entitled ELECTROSURGICAL HEMOSTATICDEVICE to Yates et al., and U.S. Pat. No. 5,688,270, entitledELECTROSURGICAL HEMOSTATIC DEVICE WITH RECESSED AND/OR OFFSET ELECTRODESto Yates et al., which are incorporated herein by reference, disclose anendoscopic cutting instrument that uses RF energy to seal the severedtissue. Published U.S. Patent Application Publication No. 2007/0102453to Jerome R. Morgan et al., now U.S. Pat. No. 7,673,783, and publishedU.S. Patent Application Publication No. 2007/0102452 to Frederick E.Shelton, I V et al., now U.S. Pat. No. 7,607,557, which are alsoincorporated herein by reference, disclose endoscopic cuttinginstruments that use adhesives to fasten the severed tissue.Accordingly, although the description herein refers to cutting/staplingoperations and the like below, it should be recognized that this is anexemplary embodiment and is not meant to be limiting. Othertissue-fastening techniques may also be used.

FIGS. 4 and 5 are exploded views and FIG. 6 is a side view of the endeffector 12 and shaft 8 according to various embodiments. As shown inthe illustrated embodiment, the shaft 8 may include a proximate closuretube 40 and a distal closure tube 42 pivotably linked by a pivot links44. The distal closure tube 42 includes an opening 45 into which the tab27 on the anvil 24 is inserted in order to open and close the anvil 24,as further described below. Disposed inside the closure tubes 40, 42 maybe a proximate spine tube 46. Disposed inside the proximate spine tube46 may be a main rotational (or proximate) drive shaft 48 thatcommunicates with a secondary (or distal) drive shaft 50 via a bevelgear assembly 52. The secondary drive shaft 50 is connected to a drivegear 54 that engages a proximate drive gear 56 of the helical screwshaft 36. The vertical bevel gear 52 b may sit and pivot in an opening57 in the distal end of the proximate spine tube 46. A distal spine tube58 may be used to enclose the secondary drive shaft 50 and the drivegears 54, 56. Collectively, the main drive shaft 48, the secondary driveshaft 50, and the articulation assembly (e.g., the bevel gear assembly52 a-c) are sometimes referred to herein as the “main drive shaftassembly.”

A bearing 38, positioned at a distal end of the staple channel 22,receives the helical drive screw 36, allowing the helical drive screw 36to freely rotate with respect to the channel 22. The helical screw shaft36 may interface a threaded opening (not shown) of the knife 32 suchthat rotation of the shaft 36 causes the knife 32 to translate distallyor proximately (depending on the direction of the rotation) through thestaple channel 22. Accordingly, when the main drive shaft 48 is causedto rotate by actuation of the firing trigger 20 (as explained in moredetail below), the bevel gear assembly 52 a-c causes the secondary driveshaft 50 to rotate, which in turn, because of the engagement of thedrive gears 54, 56, causes the helical screw shaft 36 to rotate, whichcauses the knife driving member 32 to travel longitudinally along thechannel 22 to cut any tissue clamped within the end effector. The sled33 may be made of, for example, plastic, and may have a sloped distalsurface. As the sled 33 traverses the channel 22, the sloped forwardsurface may push up or drive the staples in the staple cartridge throughthe clamped tissue and against the anvil 24. The anvil 24 turns thestaples, thereby stapling the severed tissue. When the knife 32 isretracted, the knife 32 and sled 33 may become disengaged, therebyleaving the sled 33 at the distal end of the channel 22.

FIGS. 7-10 illustrate an exemplary embodiment of a motor-drivenendocutter. The illustrated embodiment provides user-feedback regardingthe deployment and loading force of the cutting instrument in the endeffector. In addition, the embodiment may use power provided by the userin retracting the firing trigger 20 to power the device (a so-called“power assist” mode). As shown in the illustrated embodiment, the handle6 includes exterior lower sidepieces 59, 60 and exterior upper sidepieces 61, 62 that fit together to form, in general, the exterior of thehandle 6. A battery 64, such as a Li ion battery, may be provided in thepistol grip portion 26 of the handle 6. The battery 64 powers anelectric motor 65 disposed in an upper portion of the pistol gripportion 26 of the handle 6. According to various embodiments, a numberof battery cells connected in series may be used to power the motor 65.

The motor 65 may be a brushed driving motor having a maximum rotation ofapproximately 25,000 RPM with no load. In other embodiments, the motor65 may include a brushless motor, a cordless motor, a synchronous motor,a stepper motor, or any other suitable electric motor. The motor 64 maydrive a 90° bevel gear assembly 66 comprising a first bevel gear 68 anda second bevel gear 70. The bevel gear assembly 66 may drive a planetarygear assembly 72. The planetary gear assembly 72 may include a piniongear 74 connected to a drive shaft 76. The pinion gear 74 may drive amating ring gear 78 that drives a helical gear drum 80 via a drive shaft82. A ring 84 may be threaded on the helical gear drum 80. Thus, whenthe motor 65 rotates, the ring 84 is caused to travel along the helicalgear drum 80 by means of the interposed bevel gear assembly 66,planetary gear assembly 72, and ring gear 78.

The handle 6 may also include a run motor sensor 110 in communicationwith the firing trigger 20 to detect when the firing trigger 20 has beendrawn in (or “closed”) toward the pistol grip portion 26 of the handle 6by the operator to thereby actuate the cutting/stapling operation by theend effector 12. The sensor 110 may be a proportional sensor such as,for example, a rheostat, or variable resistor. When the firing trigger20 is drawn in, the sensor 110 detects the movement, and sends anelectrical signal indicative of the voltage (or power) to be supplied tothe motor 65. When the sensor 110 is a variable resistor or the like,the rotation of the motor 65 may be generally proportional to the amountof movement of the firing trigger 20. That is, if the operator onlydraws or closes the firing trigger 20 in a little bit, the rotation ofthe motor 65 is relatively low. When the firing trigger 20 is fullydrawn in (or in the fully closed position), the rotation of the motor 65is at its maximum. In other words, the harder the user pulls on thefiring trigger 20, the more voltage is applied to the motor 65, causinggreater rates of rotation.

The handle 6 may include a middle handle piece 104 adjacent to the upperportion of the firing trigger 20. The handle 6 also may comprise a biasspring 112 connected between posts on the middle handle piece 104 andthe firing trigger 20. The bias spring 112 may bias the firing trigger20 to its fully open position. In that way, when the operator releasesthe firing trigger 20, the bias spring 112 will pull the firing trigger20 to its open position, thereby removing actuation of the sensor 110,thereby stopping rotation of the motor 65. Moreover, by virtue of thebias spring 112, any time a user closes the firing trigger 20, the userwill experience resistance to the closing operation, thereby providingthe user with feedback as to the amount of rotation exerted by the motor65. Further, the operator could stop retracting the firing trigger 20 toremove thereby force from the sensor 100, to thereby stop the motor 65.As such, the user may stop the deployment of the end effector 12,thereby providing a measure of control of the cutting/fasteningoperation to the operator.

The distal end of the helical gear drum 80 includes a distal drive shaft120 that drives a ring gear 122, which mates with a pinion gear 124. Thepinion gear 124 is connected to the main drive shaft 48 of the maindrive shaft assembly. In that way, rotation of the motor 65 causes themain drive shaft assembly to rotate, which causes actuation of the endeffector 12, as described above.

The ring 84 threaded on the helical gear drum 80 may include a post 86that is disposed within a slot 88 of a slotted arm 90. The slotted arm90 has an opening 92 its opposite end 94 that receives a pivot pin 96that is connected between the handle exterior side pieces 59, 60. Thepivot pin 96 is also disposed through an opening 100 in the firingtrigger 20 and an opening 102 in the middle handle piece 104.

In addition, the handle 6 may include a reverse motor (or end-of-strokesensor) 130 and a stop motor (or beginning-of-stroke) sensor 142. Invarious embodiments, the reverse motor sensor 130 may be a limit switchlocated at the distal end of the helical gear drum 80 such that the ring84 threaded on the helical gear drum 80 contacts and trips the reversemotor sensor 130 when the ring 84 reaches the distal end of the helicalgear drum 80. The reverse motor sensor 130, when activated, sends asignal to the motor 65 to reverse its rotation direction, therebywithdrawing the knife 32 of the end effector 12 following the cuttingoperation. The stop motor sensor 142 may be, for example, a normallyclosed limit switch. In various embodiments, it may be located at theproximate end of the helical gear drum 80 so that the ring 84 trips theswitch 142 when the ring 84 reaches the proximate end of the helicalgear drum 80.

In operation, when an operator of the instrument 10 pulls back thefiring trigger 20, the sensor 110 detects the deployment of the firingtrigger 20 and sends a signal to the motor 65 to cause forward rotationof the motor 65 at, for example, a rate proportional to how hard theoperator pulls back the firing trigger 20. The forward rotation of themotor 65 in turn causes the ring gear 78 at the distal end of theplanetary gear assembly 72 to rotate, thereby causing the helical geardrum 80 to rotate, causing the ring 84 threaded on the helical gear drum80 to travel distally along the helical gear drum 80. The rotation ofthe helical gear drum 80 also drives the main drive shaft assembly asdescribed above, which in turn causes deployment of the knife 32 in theend effector 12. That is, the knife 32 and sled 33 are caused totraverse the channel 22 longitudinally, thereby cutting tissue clampedin the end effector 12. Also, the stapling operation of the end effector12 is caused to happen in embodiments where a stapling-type end effectoris used.

By the time the cutting/stapling operation of the end effector 12 iscomplete, the ring 84 on the helical gear drum 80 will have reached thedistal end of the helical gear drum 80, thereby causing the reversemotor sensor 130 to be tripped, which sends a signal to the motor 65 tocause the motor 65 to reverse its rotation. This in turn causes theknife 32 to retract, and also causes the ring 84 on the helical geardrum 80 to move back to the proximate end of the helical gear drum 80.

The middle handle piece 104 includes a backside shoulder 106 thatengages the slotted arm 90 as best shown in FIGS. 8 and 9. The middlehandle piece 104 also has a forward motion stop 107 that engages thefiring trigger 20. The movement of the slotted arm 90 is controlled, asexplained above, by rotation of the motor 65. When the slotted arm 90rotates CCW as the ring 84 travels from the proximate end of the helicalgear drum 80 to the distal end, the middle handle piece 104 will be freeto rotate CCW. Thus, as the user draws in the firing trigger 20, thefiring trigger 20 will engage the forward motion stop 107 of the middlehandle piece 104, causing the middle handle piece 104 to rotate CCW. Dueto the backside shoulder 106 engaging the slotted arm 90, however, themiddle handle piece 104 will only be able to rotate CCW as far as theslotted arm 90 permits. In that way, if the motor 65 should stoprotating for some reason, the slotted arm 90 will stop rotating, and theuser will not be able to further draw in the firing trigger 20 becausethe middle handle piece 104 will not be free to rotate CCW due to theslotted arm 90.

Components of an exemplary closure system for closing (or clamping) theanvil 24 of the end effector 12 by retracting the closure trigger 18 arealso shown in FIGS. 7-10. In the illustrated embodiment, the closuresystem includes a yoke 250 connected to the closure trigger 18 by a pin251 that is inserted through aligned openings in both the closuretrigger 18 and the yoke 250. A pivot pin 252, about which the closuretrigger 18 pivots, is inserted through another opening in the closuretrigger 18 which is offset from where the pin 251 is inserted throughthe closure trigger 18. Thus, retraction of the closure trigger 18causes the upper part of the closure trigger 18, to which the yoke 250is attached via the pin 251, to rotate CCW. The distal end of the yoke250 is connected, via a pin 254, to a first closure bracket 256. Thefirst closure bracket 256 connects to a second closure bracket 258.Collectively, the closure brackets 256, 258 define an opening in whichthe proximate end of the proximate closure tube 40 (see FIG. 4) isseated and held such that longitudinal movement of the closure brackets256, 258 causes longitudinal motion by the proximate closure tube 40.The instrument 10 also includes a closure rod 260 disposed inside theproximate closure tube 40. The closure rod 260 may include a window 261into which a post 263 on one of the handle exterior pieces, such asexterior lower sidepiece 59 in the illustrated embodiment, is disposedto fixedly connect the closure rod 260 to the handle 6. In that way, theproximate closure tube 40 is capable of moving longitudinally relativeto the closure rod 260. The closure rod 260 may also include a distalcollar 267 that fits into a cavity 269 in proximate spine tube 46 and isretained therein by a cap 271 (see FIG. 4).

In operation, when the yoke 250 rotates due to retraction of the closuretrigger 18, the closure brackets 256, 258 cause the proximate closuretube 40 to move distally (i.e., away from the handle end of theinstrument 10), which causes the distal closure tube 42 to movedistally, which causes the anvil 24 to rotate about the pivot point 25into the clamped or closed position. When the closure trigger 18 isunlocked from the locked position, the proximate closure tube 40 iscaused to slide proximately, which causes the distal closure tube 42 toslide proximately, which, by virtue of the tab 27 being inserted in thewindow 45 of the distal closure tube 42, causes the anvil 24 to pivotabout the pivot point 25 into the open or unclamped position. In thatway, by retracting and locking the closure trigger 18, an operator mayclamp tissue between the anvil 24 and channel 22, and may unclamp thetissue following the cutting/stapling operation by unlocking the closuretrigger 20 from the locked position.

Additional configurations for motorized surgical instruments aredisclosed in published U.S. Patent Application Publication No.2007/0175962, entitled MOTOR-DRIVEN SURGICAL CUTTING AND FASTENINGINSTRUMENT WITH TACTILE POSITION FEEDBACK, now U.S. Pat. No. 7,422,139,which is incorporated herein by reference in its entirety.

FIG. 11 is a schematic diagram of the motor control circuit according tovarious embodiments of the present invention. In various embodiments,the motor control circuit may include one of more integrated circuits(ICs), such as, for example, a processor, memory, microcontroller, timecircuits, etc. In other embodiments, the motor control circuit may notcomprise any ICs. Such a non-IC motor control circuit may beadvantageous because it is often difficult, complicated, and expensiveto sterilize a surgical instrument including ICs.

When an operator initially pulls in the firing trigger 20 after lockingthe closure trigger 18, the sensor 110 is activated (or closed, wherethe sensor 110 is a switch), allowing current to flow therethrough. Ifthe normally open reverse motor sensor switch 130 is open (meaning theend of the end effector stroke has not been reached), current will flowto a single pole, double throw relay 132. When the reverse motor sensorswitch 130 is not closed, a coil 134 of the relay 132 will not beenergized, so the relay 132 will be in its de-energized state.

As shown in FIG. 11, the circuit may also include a resistive element144 and a switch 146 connected in parallel, with the paralleled elementsconnected in series with the relay 132. The resistive element 144 andthe switch 146 are also connected to the power source 64. The switch 146may be controlled by a control circuit 148 that is responsive to thecutting instrument position sensor 150. According to variousembodiments, the control circuit 148 may open the switch 146 when thecutting instrument 32 is (i) very near to the beginning of its strokeand (ii) very near to the end of its stroke. For example, the controlcircuit may open the switch when the cutting instrument 32 is (i) 0.001inches from the beginning point of its stroke and (ii) 0.001 inches fromthe end of its stroke, as determined by the cutting instrument positionsensor 150. With the switch 146 open, current flows through theresistive element 144, and then through the relay 132, the relay 138,the run motor sensor switch 110, to the motor 65. Current flowingthrough the resistive element 144 reduces the magnitude of the currentdelivered to the motor 65, thereby reducing the power delivered by themotor 65. Thus, when the cutting instrument 32 is (i) very near to thebeginning of its stroke or (ii) very near to the end of its stroke, thepower delivered by the motor 65 is reduced. Conversely, once the cuttinginstrument 32 moves sufficiently far from its beginning point or end ofstroke point, the control circuit 148 may close the switch 146, therebyshorting the resistive element 144, thereby increasing the current tothe motor 65, thereby increasing the power delivered by the motor.

According to various embodiments, the electrical circuit furtherincludes lockout sensor switches 136 a-d collectively defining aninterlock circuit 137 through which current from the relay 132, whende-energized, passes in order for electrical operation of the motor 65to be initiated. Each lockout sensor switch 136 a-d may be configured tomaintain an open (i.e., non-conductive) switch state or a closed (i.e.,conductive) switch state responsive to the presence or absence,respectively, of a corresponding condition. Any of the correspondingconditions, if present when the instrument 10 is fired, may result in anunsatisfactory cutting and stapling operation and/or damage to theinstrument 10. Conditions to which the lockout sensor switches 136 a-dmay respond include, for example, (a) the absence of the staplecartridge 34 in the channel 22, (b) the presence of a spent (e.g.,previously fired) staple cartridge 34 in the channel 22, and (c) an open(or otherwise insufficiently closed) position of the anvil 24 withrespect to the channel 22. Other conditions to which the lockout sensorswitches 136 a-d may respond, such as component wear, may be inferredbased upon an accumulated number of firing operations produced by theinstrument 10. Accordingly, in various embodiments, if any of theseconditions exists, the corresponding lockout sensor switches 136 a-dmaintain an open switch state, thus preventing passage of the currentnecessary to initiate operation of the motor 65. Passage of current bythe lockout sensors 136 a-d is allowed, in various embodiments, onlyafter all of the conditions have been remedied. It will be appreciatedthat the above-described conditions are provided by way of example only,and that additional lockout sensor switches for responding to otherconditions detrimental to operation of the instrument 10 may beprovided. It will similarly be appreciated that for embodiments in whichone or more of the above-described conditions may not exist or are of noconcern, the number of lockout sensor switches may be fewer than thatdepicted.

As shown in FIG. 11, the lockout sensor switch 136 a may be implementedusing a normally open switch configuration such that a closed switchstate is maintained when the staple cartridge 34 is in a positioncorresponding to its proper receipt by the channel 22. When the staplecartridge 34 is not installed in the channel 22, or is installedimproperly (e.g., misaligned), the lockout sensor switch 136 a maintainsan open switch state. Lockout sensor switch 136 b may be implementedusing a normally open switch configuration such that a closed switchstate is maintained only when an unspent staple cartridge 34 (i.e., astaple cartridge 34 having a sled 33 in the unfired position) is presentin the channel 22. The presence of a spent staple cartridge 34 in thechannel 22 causes the lockout sensor switch 136 b to maintain an openswitch state. Lockout sensor switch 136 c may be implemented using anormally open switch configuration such that a closed switch state ismaintained when the anvil 24 is in a closed position with respect to thechannel 22. The lockout sensor switch 136 c may be controlled inaccordance with a time delay feature wherein a closed switch state ismaintained only after the anvil 24 is in the closed position for apre-determined period of time.

Lockout sensor switch 136 d may be implemented using a normally closedswitch configuration such that a closed switch state is maintained onlywhen an accumulated number of firings produced by the instrument 10 isless than a pre-determined number. The lockout sensor switch 136 d maybe in communication with a counter 139 configured for maintaining acount representative of the accumulated number of firing operationsperformed by the instrument 10, comparing the count to thepre-determined number, and controlling the switch state of the lockoutsensor switch 136 d based upon the comparison. Although shown separatelyin FIG. 11, it will be appreciated that counter 139 may be integral withthe lockout sensor switch 136 d so as to form a common device.Preferably, the counter 139 is implemented as an electronic devicehaving an input for incrementing the maintained count based upon thetransition of a discrete electrical signal provided thereto. It will beappreciated that a mechanical counter configured for maintaining thecount based upon a mechanical input (e.g., retraction of the firingtrigger 20) may be used instead. When implemented as an electronicdevice, any discrete signal present in the electrical circuit thattransitions once for each firing operation may be utilized for thecounter 139 input. As shown in FIG. 11, for example, the discreteelectrical signal resulting from actuation of the end-of-stroke sensor130 may be utilized. The counter 139 may control the switch state oflockout sensor switch 136 d such that a closed switch state ismaintained when the maintained count is less than a pre-determinednumber stored within the counter 139. When the maintained count is equalto the pre-determined number, the counter 139 causes the lockout sensorswitch 136 d to maintain an open switch state, thus preventing thepassage of current therethrough. It will be appreciated that thepre-determined number stored by the counter 139 may be selectivelyadjusted as required. According to various embodiments, the counter 304may be in communication with an external display (not shown), such as anLCD display, integral to the instrument 10 for indicating to a usereither the maintained count or the difference between the pre-determinednumber and the maintained count.

According to various embodiments, the interlock circuit 137 may compriseone or more indicators visible to the user of the instrument 10 fordisplaying a status of at least one of the lockout sensor switches 136a-d. More details regarding such indicators may be found in publishedU.S. Patent Application Publication No. 2007/0175956, entitledELECTRONIC LOCKOUTS AND SURGICAL INSTRUMENT INCLUDING SAME, now U.S.Pat. No. 7,644,848, which is incorporated herein by reference in itsentirety. This application also includes example mounting arrangementsand configurations for the lockout sensor switches 136 a-d.

In the illustrated embodiment, when the lockout sensor switches 136 a-dcollectively maintain a closed switch state, a single pole, single throwrelay 138 is energized. When the relay 138 is energized, current flowsthrough the relay 138, through the run motor switch sensor 110, and tothe motor 65 via a double pole, double throw relay 140, thereby poweringthe motor 65, allowing it to rotate in the forward direction. Accordingto various embodiments, because the output of the relay 138, onceenergized, maintains the relay 138 in an energized state until relay 132is energized, the interlock circuit 137 will not function to preventoperation of the motor 165 once initiated, even if one or more of theinterlock sensor switches 136 a-d subsequently maintains an open switchstate. In other embodiments, however, it may be necessary or otherwisedesirable to connect the interlock circuit 137 and the relay 138 suchthat one or more the lockout sensor switches 136 a-d must maintain aclosed switch state in order to sustain operation of the motor 165 onceinitiated.

Rotation of the motor in the forward direction causes the ring 84 tomove distally and thereby de-actuate the stop motor sensor switch 142 invarious embodiments. Because the switch 142 is normally closed, asolenoid 141 connected to the switch 142 may be energized. The solenoid141 may be a conventional push-type solenoid that, when energized,causes a plunger (not shown) to be axially extended. Extension of theplunger may operate to retain the closure trigger 18 in the retractedposition, thus preventing the anvil 24 from opening while a firingoperation is in progress (i.e., while the switch 142 is not actuated).Upon deenergization of the solenoid 141, the plunger is retracted suchthat manual release of the closure trigger 18 is possible.

When the end effector 12 reaches the end of its stroke, the reversemotor sensor 130 will be activated, thereby closing the switch 130 andenergizing the relay 132. This causes the relay 132 to assume itsenergized state (not shown in FIG. 11), which causes current to bypassthe interlock circuit 137 and run motor sensor switch 110, and insteadcauses current to flow to both the normally-closed double pole, doublethrow relay 140 and back to the motor 65, but in a manner, via the relay140, that causes the motor 65 to reverse its rotational direction.Because the stop motor sensor switch 142 is normally closed, currentwill flow back to the relay 132 to keep it energized until the switch142 opens. When the knife 32 is fully retracted, the stop motor sensorswitch 142 is activated, causing the switch 142 to open, therebyremoving power from the motor 65, and de-energizing the solenoid 141.

In other embodiments, other alternatives may be used to limit thecurrent supplied to the motor 65 during certain time periods during thecutting stroke cycle. Other embodiments are described in U.S. PatentApplication Ser. No. 12/235,782, now U.S. Pat. No. 8,210,411, which isincorporated herein by reference in its entirety.

In some instances, it may be advantageous to provide a momentaryincrease in current to the motor 65 to increase the output torque. FIG.19 shows an embodiment of a circuit for providing a momentary increaseto the motor 65 according to various embodiments. The circuit is similarto that shown in FIG. 11, except that the circuit of FIG. 19additionally includes a charge accumulator device 1000 connected to thepower source 64. The charge accumulator device 1000 may be any devicethat can store charge, such as a capacitor. For example, the chargeaccumulator device 1000 may comprise an ultracapacitor (sometimes calleda supercapacitor). When the motor 65 is first turned on, such as whenthe switch 110 is closed due to retraction of the firing trigger 20, theswitch 51 may be closed so that the battery 64 can power the motor 65 asdescribed above. In addition, the switch S3 may also be closed for onlya brief period of time (“the charging period”) to charge the chargeaccumulator device 1000 via the resistor R1. For example, according tovarious embodiments, the switch S3 may be closed for one to ten RC timeconstants, where R is the resistance of the resistor R1 and C is thecapacitance of the charge accumulator device 1000.

The charge in the charge accumulator device 1000 may remain unusedduring normal operating conditions, but if there comes a time in theprocedure where the clinician needs additional output torque from themotor 65, the charge accumulator device 1000 could be put in series withthe battery 64. This could be done, for example, by opening switch S1and closing switch S2 (with S3 remaining open following the chargingperiod). With switch S2 closed, the charge accumulator device 1000 wouldbe connected in series with the battery 64, thereby supplying additionalcurrent to the motor 65.

The condition requiring the charge accumulator device 1000 may bedetected in numerous ways. For example, there may be a variable resistoror spring connected to the firing trigger 20. When the firing trigger isretracted beyond a certain point or with a force above a thresholdlevel, the charge accumulator device 1000 may be connected in series tothe battery 64. Additionally or alternatively, the handle 6 may comprisean external switch (not shown) that the clinician could activate toconnect the charge accumulator device 1000 in series with battery 64.

The charge accumulator device 1000 could be used with or without thecurrent limiting devices described above in connection with FIG. 11.

At some times during use of the instrument 10, it may be advantageous tohave the motor 65 run at high speed but relatively low torque output. Atother times, it may be desirable to have the motor 65 have a high torqueoutput but at low speeds. According to various embodiments, thisfunctionality may be accomplished with a motor 65 having multiple (e.g.,two or more) windings, as shown in FIG. 20. In the illustratedembodiment, the motor has two windings. A first winding 1200 may havewinding halves (or portions) 1201 and 1202. A second winding 1204 mayhave winding halves (or portions) 1206 and 1208. The motor 65 in thisexample may be a 6 or 8 lead motor with a bipolar driving circuit 1210(see FIGS. 11 and 12, for example). When the high-speed low-torque modeis desired, the two sets of winding may be connected in series. In thismode, as shown in FIG. 20, switches S1 and S4 are closed, and switchesS2, S3, S5, and S6 are open. When the low-speed high-torque mode isdesired, the two sets of windings may be connected in parallel. In thismode, switches S1 and S4 are open, and switches S2, S3, S5, and S6 areclosed. The ability to transition between the two modes effectivelycreates a two-speed transmission with no additional moving parts. Italso allows the same motor to generate both high speeds and high torqueoutputs, albeit not at the same time. An advantage of this configurationis that it avoids using multiple motors. In addition, it may be possibleto eliminate some gearing because the motor 65 can generate extra torquewhen in the parallel mode and extra speed when in the series mode. Inaddition, additional windings could be employed such that a greaternumber of operating modes may be realized. For example, there could bewindings for multiple combinations of series and parallel windingconnections. Also, some windings may be used for sensing motorconditions, etc.

According to various embodiments, the handle 6 may comprise an externalmotor mode selection switch 1220, as shown in FIG. 21. By using theswitch 1220, the operator of the instrument 10 could select with themotor 65 is in the high-speed low-torque mode or in the low-speedhigh-torque mode. Other switching circuits could also be used to togglethe motor 65 between the operating modes, such as switching circuitsthat automatically switch the motor mode based on sensor inputs.

In a motorized surgical instrument, such as one of the motorizedendoscopic instruments described above or in a motorized circular cutterinstrument, the motor may be powered by a number of battery cellsconnected in series. Further, it may be desirable in certaincircumstances to power the motor with some fraction of the total numberof battery cells. For example, as shown in FIG. 12, the motor 65 may bepowered by a power pack 299 comprising six (6) battery cells 310connected in series. The battery cells 310 may be, for example, 3-voltlithium battery cells, such as CR 123A battery cells, although in otherembodiments, different types of battery cells could be used (includingbattery cells with different voltage levels and/or differentchemistries). If six 3-volt battery cells 310 were connected in seriesto power the motor 65, the total voltage available to power the motor 65would be 18 volts. The battery cells 310 may comprise rechargeable ornon-rechargeable battery cells.

In such an embodiment, under the heaviest loads, the input voltage tothe motor 65 may sag to about nine to ten volts. At this operatingcondition, the power pack 299 is delivering maximum power to the motor65. Accordingly, as shown in FIG. 12, the circuit may include a switch312 that selectively allows the motor 65 to be powered by either (1) allof the battery cells 310 or (2) a fraction of the battery cells 310. Asshown in FIG. 12, by proper selection, the switch 312 may allow themotor 65 to be powered by all six battery cells or four of the batterycells. That way, the switch 312 could be used to power the motor 65 witheither 18 volts (when using all six battery cells 310) or 12 volts (suchusing four of the second battery cells). In various embodiments, thedesign choice for the number of battery cells in the fraction that isused to power the motor 65 may be based on the voltage required by themotor 65 when operating at maximum output for the heaviest loads.

The switch 312 may be, for example, an electromechanical switch, such asa micro switch. In other embodiments, the switch 312 may be implementedwith a solid-state switch, such as transistor. A second switch 314, suchas a push button switch, may be used to control whether power is appliedto the motor 65 at all. Also, a forward/reverse switch 316 may be usedto control whether the motor 65 rotates in the forward direction or thereverse direction. The forward/reverse switch 316 may be implementedwith a double pole-double throw switch, such as the relay 140 shown inFIG. 11.

In operation, the user of the instrument 10 could select the desiredpower level by using some sort of switch control, such as aposition-dependent switch (not shown), such as a toggle switch, amechanical lever switch, or a cam, which controls the position of theswitch 312. Then the user may activate the second switch 314 to connectthe selected battery cells 310 to the motor 65. In addition, the circuitshown in FIG. 12 could be used to power the motor of other types ofmotorized surgical instruments, such as circular cutters and/orlaparoscopic instruments. More details regarding circular cutters may befound in published U.S. Patent Application Publication No. 2006/0047307,now U.S. Pat. No. 8,317,074, and published U.S. Patent ApplicationPublication No. 2007/0262116, now U.S. Pat. No. 7,500,979, which areincorporated herein by reference.

In other embodiments, as shown in FIG. 13, a primary power source 340,such as a battery cell, such as a CR2 or CR123A battery cell, may beused to charge a number of secondary accumulator devices 342. Theprimary power source 340 may comprise one or a number ofseries-connected battery cells, which are preferably replaceable in theillustrated embodiment. The secondary accumulator devices 342 maycomprise, for example, rechargeable battery cells and/or supercapacitors(also known as “ultracapacitors” or “electrochemical double layercapacitors” (EDLC)). Supercapacitors are electrochemical capacitors thathave an unusually high energy density when compared to commonelectrolytic capacitors, typically on the order of thousands of timesgreater than a high-capacity electrolytic capacitor.

The primary power source 340 may charge the secondary accumulatordevices 342. Once sufficiently charged, the primary power source 340 maybe removed and the secondary accumulator devices 342 may be used topower the motor 65 during a procedure or operation. The accumulatingdevices 342 may take about fifteen to thirty minutes to charge invarious circumstances. Supercapacitors have the characteristic they cancharge and discharge extremely rapidly in comparison to conventionalbatteries. In addition, whereas batteries are good for only a limitednumber of charge/discharge cycles, supercapacitors can often becharged/discharged repeatedly, sometimes for tens of millions of cycles.For embodiments using supercapacitors as the secondary accumulatordevices 342, the supercapacitors may comprise carbon nanotubes,conductive polymers (e.g., polyacenes), or carbon aerogels.

As shown in FIG. 14, a charge management circuit 344 could be employedto determine when the secondary accumulator devices 342 are sufficientlycharged. The charge management circuit 344 may include an indicator,such as one or more LEDs, an LCD display, etc., that is activated toalert a user of the instrument 10 when the secondary accumulator devices342 are sufficiently charged.

The primary power source 340, the secondary accumulator devices 342, andthe charge management circuit 344 may be part of a power pack in thepistol grip portion 26 of the handle 6 of the instrument 10, or inanother part of the instrument 10. The power pack may be removable fromthe pistol grip portion 26, in which case, when the instrument 10 is tobe used for surgery, the power pack may be inserted aseptically into thepistol grip portion 26 (or other position in the instrument according toother embodiments) by, for example, a circulating nurse assisting in thesurgery. After insertion of the power pack, the nurse could put thereplaceable primary power source 340 in the power pack to charge up thesecondary accumulator devices 342 a certain time period prior to use ofthe instrument 10, such as thirty minutes. When the secondaryaccumulator devices 342 are charged, the charge management circuit 344may indicate that the power pack is ready for use. At this point, thereplaceable primary power source 340 may be removed. During theoperation, the user of the instrument 10 may then activate the motor 65,such as by activating the switch 314, whereby the secondary accumulatordevices 342 power the motor 65. Thus, instead of having a number ofdisposable batteries to power the motor 65, one disposable battery (asthe primary power source 340) could be used in such an embodiment, andthe secondary accumulator devices 342 could be reusable. In alternativeembodiments, however, it should be noted that the secondary accumulatordevices 342 could be non-rechargeable and/or non-reusable. The secondaryaccumulators 342 may be used with the cell selection switch 312described above in connection with FIG. 12.

The charge management circuit 344 may also include indicators (e.g.,LEDs or LCD display) that indicate how much charge remains in thesecondary accumulator devices 342. That way, the surgeon (or other userof the instrument 10) can see how much charge remains through the courseof the procedure involving the instrument 10.

The charge management circuit 344, as shown in FIG. 15, may comprise acharge meter 345 for measuring the charge across the secondaryaccumulators 342. The charge management circuit 344 also may comprise anon-volatile memory 346, such as flash or ROM memory, and one or moreprocessors 348. The processor(s) 348 may be connected to the memory 346to control the memory. In addition, the processor(s) 348 may beconnected to the charge meter 345 to read the readings of and otherwisecontrol the charge meter 345. Additionally, the processor(s) 348 maycontrol the LEDs or other output devices of the charge managementcircuit 344. The processor(s) 348 can store parameters of the instrument10 in the memory 346. The parameters may include operating parameters ofthe instrument that are sensed by various sensors that may be installedor employed in the instrument 10, such as, for example, the number offirings, the levels of forces involved, the distance of the compressiongap between the opposing jaws of the end effector 12, the amount ofarticulation, etc. Additionally, the parameters stored in the memory 346may comprise ID values for various components of the instrument 10 thatthe charge management circuit 344 may read and store. The componentshaving such IDs may be replaceable components, such as the staplecartridge 34. The IDs may be for example, RFIDs that the chargemanagement circuit 344 reads via a RFID transponder 350. The RFIDtransponder 350 may read RFIDs from components of the instrument, suchas the staple cartridge 34, that include RFID tags. The ID values may beread, stored in the memory 346, and compared by the processor 348 to alist of acceptable ID values stored in the memory 346 or another storeassociated with the charge management circuit, to determine, forexample, if the removable/replaceable component associated with the readID value is authentic and/or proper. According to various embodiments,if the processor 348 determines that the removable/replaceable componentassociated with the read ID value is not authentic, the chargemanagement circuit 344 may prevent use of the power pack by theinstrument 10, such as by opening a switch (not shown) that wouldprevent power from the power pack being delivered to the motor 65.According to various embodiments, various parameters that the processor348 may evaluate to determine whether the component is authentic and/orproper include: date code; component model/type; manufacturer; regionalinformation; and previous error codes.

The charge management circuit 344 may also comprise an i/o interface 352for communicating with another device, such as described below. Thatway, the parameters stored in the memory 346 may be downloaded toanother device. The i/o interface 352 may be, for example, a wired orwireless interface.

As mentioned before, the power pack may comprise the secondaryaccumulators 342, the charge management circuit 344, and/or the f/rswitch 316. According to various embodiments, as shown in FIG. 16, thepower pack 299 could be connected to a charger base 362, which may,among other things, charge the secondary accumulators 342 in the powerpack. The charger base 362 could be connected to the power pack 299 byconnecting aseptically the charger base 362 to the power pack 299 whilethe power pack is installed in the instrument 10. In other embodimentswhere the power pack is removable, the charger base 362 could beconnected to the power pack 299 by removing the power pack 299 from theinstrument 10 and connecting it to the charger base 362. For suchembodiments, after the charger base 362 sufficiently charges thesecondary accumulators 342, the power pack 299 may be asepticallyinstalled in the instrument 10.

As shown in FIG. 16, the charger base 362 may comprise a power source364 for charging the secondary accumulators 342. The power source 364 ofthe charger base 362 may be, for example, a battery (or a number ofseries-connected batteries), or an AC/DC converter that converters ACpower, such as from electrical power mains, to DC, or any other suitablepower source for charging the secondary accumulators 342. The chargerbase 362 may also comprise indicator devices, such as LEDs, a LCDdisplay, etc., to show the charge status of the secondary accumulators342.

In addition, as shown in FIG. 16, the charger base 362 may comprise oneor more processors 366, one or more memory units 368, and i/o interfaces370, 372. Through the first i/o interface 370, the charger base 362 maycommunicate with the power pack 299 (via the power pack's i/o interface352). That way, for example, data stored in the memory 346 of the powerpack 299 may be downloaded to the memory 368 of the charger base 362. Inthat way, the processor 366 can evaluate the ID values for theremovable/replaceable components, downloaded from the charge managementcircuit 344, to determine the authenticity and suitability of thecomponents. The operating parameters downloaded from the chargemanagement circuit 344 may also stored in the memory 368, and then maythen be downloaded to another computer device via the second i/ointerface 372 for evaluation and analysis, such as by the hospitalsystem in which the operation involving the instrument 10 is performed,by the office of the surgeon, by the distributor of the instrument, bythe manufacturer of the instrument, etc.

The charger base 362 may also comprise a charge meter 374 for measuringthe charge across the secondary accumulators 342. The charge meter 374may be in communication with the processor(s) 366, so that theprocessor(s) 366 can determine in real-time the suitability of the powerpack 299 for use to ensure high performance.

In another embodiment, as shown in FIG. 17, the battery circuit maycomprise a power regulator 320 to control the power supplied by thepower savers 310 to the motor 65. The power regulator 320 may also bepart of the power pack 299, or it may be a separate component. Asmentioned above, the motor 65 may be a brushed motor. The speed ofbrushed motors generally is proportional to the applied input voltage.The power regulator 320 may provide a highly regulated output voltage tothe motor 65 so that the motor 65 will operate at a constant (orsubstantially constant) speed. According to various embodiments, thepower regulator 320 may comprise a switch-mode power converter, such asa buck-boost converter, as shown in the example of FIG. 17. Such abuck-boost converter 320 may comprise a power switch 322, such as a FET,a rectifier 32, an inductor 326, and a capacitor 328. When the powerswitch 322 is on, the input voltage source (e.g., the power sources 310)is directly connected to the inductor 326, which stores energy in thisstate. In this state, the capacitor 328 supplies energy to the outputload (e.g., the motor 65). When the power switch 320 is in the offstate, the inductor 326 is connected to the output load (e.g., the motor65) and the capacitor 328, so energy is transferred from the inductor326 to the capacitor 328 and the load 65. A control circuit 330 maycontrol the power switch 322. The control circuit 330 may employ digitaland/or analog control loops. In addition, in other embodiments, thecontrol circuit 330 may receive control information from a mastercontroller (not shown) via a communication link, such as a serial orparallel digital data bus. The voltage set point for the output of thepower regulator 320 may be set, for example, to one-half of the opencircuit voltage, at which point the maximum power available from thesource is available.

In other embodiments, different power converter topologies may beemployed, including linear or switch-mode power converters. Otherswitch-mode topologies that may be employed include a flyback, forward,buck, boost, and SEPIC. The set point voltage for the power regulator320 could be changed depending on how many of the battery cells arebeing used to power the motor 65. Additionally, the power regulator 320could be used with the secondary accumulator devices 342 shown in FIG.13. Further, the forward-reverse switch 316 could be incorporated intothe power regulator 320, although it is shown separately in FIG. 17.

Batteries can typically be modeled as an ideal voltage source and asource resistance. For an ideal model, when the source and loadresistance are matched, maximum power is transferred to the load. FIG.18 shows a typical power curve for a battery. When the battery circuitis open, the voltage across the battery is high (at its open circuitvalue) and the current drawn from the battery is zero. The powerdelivered from the battery is zero also. As more current is drawn fromthe battery, the voltage across the battery decreases. The powerdelivered by the battery is the product of the current and the voltage.The power reaches its peak around at a voltage level that is less thanthe open circuit voltage. As shown in FIG. 18, with most batterychemistries there is a sharp drop in the voltage/power at higher currentbecause of the chemistry or positive temperature coefficient (PTC), orbecause of a battery protection device.

Particularly for embodiments using a battery (or batteries) to power themotor 65 during a procedure, the control circuit 330 can monitor theoutput voltage and control the set point of the regulator 320 so thatthe battery operates on the “left” or power-increasing side of the powercurve. If the battery reaches the peak power level, the control circuit330 can change (e.g., lower) the set point of the regulator so that lesstotal power is being demanded from the battery. The motor 65 would thenslow down. In this way, the demand from the power pack would rarely ifever exceed the peak available power so that a power-starving situationduring a procedure could be avoided.

In addition, according to other embodiments, the power drawn from thebattery may be optimized in such a way that the chemical reactionswithin the battery cells would have time to recover, to thereby optimizethe current and power available from the battery. In pulsed loads,batteries typically provide more power at the beginning of the pulsethat toward the end of the pulse. This is due to several factors,including: (1) the PTC may be changing its resistance during the pulse;(2) the temperature of the battery may be changing; and (3) theelectrochemical reaction rate is changing due to electrolyte at thecathode being depleted and the rate of diffusion of the freshelectrolyte limits the reaction rate. According to various embodiments,the control circuit 330 may control the converter 320 so that it draws alower current from the battery to allow the battery to recover before itis pulsed again.

As mentioned above, according to various embodiments the battery pack299 may comprise multiple battery cells 310. FIG. 22 shows an embodimentwith six (6) battery cells 310. The battery cells 310 may be, forexample, lithium primary batteries. According to various embodiments,the battery pack 299 may have only a fraction of the battery cellsinternally connected. For example, as shown in FIG. 22, cell 310 a isconnected to cell 310 b, cell 310 c is connected to cell 310 d, and cell310 e is connected to cell 310 f. However, cell 310 b is not connectedinternally in the battery pack to cell 310 c, and cell 310 d is notconnected internally in the battery pack to cell 310 e. The handle 6 ofthe instrument 10 in such embodiments may comprise a battery cellconnector 1300 that connects the cells 310 in series only when thebattery pack 299 is physically inserted in the instrument 10. Forexample, the connector 1300 may comprise a positive output terminal1302, a connector 1304 that series connects cell 310 b to cell 310 c, aconnector 1306 that connects cell 310 d to cell 310 e, and a negativeoutput terminal 1308.

FIG. 23 shows an embodiment of the instrument 10 where a replaceable,removable battery pack 299 is installed in the handle 6 of theinstrument 10. As shown in FIG. 23, the battery cell connector 1300 maybe integrated into the handle 6 such that, when the battery pack 299 isinserted into the handle 6, the battery cell connector 1300 makes thenecessary battery cell connections.

Of course, in other embodiments, battery packs with a different numberof internal cells and different numbers of internally connected cellsmay be used. For example, FIG. 24 shows an embodiment with six cells 310a-f, where two sets of three cells (cells 310 a-c and cells 310 d-f) areconnected together.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, the device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, the devicecan be disassembled, and any number of the particular pieces or parts ofthe device can be selectively replaced or removed in any combination.Upon cleaning and/or replacement of particular parts, the device can bereassembled for subsequent use either at a reconditioning facility, orby a surgical team immediately prior to a surgical procedure. Thoseskilled in the art will appreciate that reconditioning of a device canutilize a variety of techniques for disassembly, cleaning/replacement,and reassembly. Use of such techniques, and the resulting reconditioneddevice, are all within the scope of the present application.

Preferably, the various embodiments of the invention described hereinwill be processed before surgery. First, a new or used instrument isobtained and if necessary cleaned. The instrument can then besterilized. In one sterilization technique, the instrument is placed ina closed and sealed container, such as a thermoformed plastic shellcovered with a sheet of TYVEK. The container and instrument are thenplaced in a field of radiation that can penetrate the container, such asgamma radiation, x-rays, or high-energy electrons. The radiation killsbacteria on the instrument and in the container. The sterilizedinstrument can then be stored in the sterile container. The sealedcontainer keeps the instrument sterile until it is opened in the medicalfacility.

It is preferred that the device is sterilized. This can be done by anynumber of ways known to those skilled in the art including beta or gammaradiation, ethylene oxide, steam and other methods.

While the present invention has been illustrated by description ofseveral embodiments and while the illustrative embodiments have beendescribed in considerable detail, it is not the intention of theapplicant to restrict or in any way limit the scope of the appendedclaims to such detail. Additional advantages and modifications mayreadily appear to those skilled in the art. The various embodiments ofthe present invention represent vast improvements over prior staplemethods that require the use of different sizes of staples in a singlecartridge to achieve staples that have differing formed (final) heights.

Accordingly, the present invention has been discussed in terms ofendoscopic procedures and apparatus. However, use herein of terms suchas “endoscopic” should not be construed to limit the present inventionto a surgical stapling and severing instrument for use only inconjunction with an endoscopic tube (i.e., trocar). On the contrary, itis believed that the present invention may find use in any procedurewhere access is limited, including but not limited to laparoscopicprocedures, as well as open procedures. Moreover, the unique and novelaspects of the various staple cartridge embodiments of the presentinvention may find utility when used in connection with other forms ofstapling apparatuses without departing from the spirit and scope of thepresent invention.

Over the years a variety of minimally invasive robotic (or“telesurgical”) systems have been developed to increase surgicaldexterity as well as to permit a surgeon to operate on a patient in anintuitive manner. Many of such systems are disclosed in the followingU.S. Patents which are each herein incorporated by reference in theirrespective entirety: U.S. Pat. No. 5,792,135, entitled ARTICULATEDSURGICAL INSTRUMENT FOR PERFORMING MINIMALLY INVASIVE SURGERY WITHENHANCED DEXTERITY AND SENSITIVITY, U.S. Pat. No. 6,231,565, entitledROBOTIC ARM DLUS FOR PERFORMING SURGICAL TASKS, U.S. Pat. No. 6,783,524,entitled ROBOTIC SURGICAL TOOL WITH ULTRASOUND CAUTERIZING AND CUTTINGINSTRUMENT, U.S. Pat. No. 6,364,888, entitled ALIGNMENT OF MASTER ANDSLAVE IN A MINIMALLY INVASIVE SURGICAL APPARATUS, U.S. Pat. No.7,524,320, entitled MECHANICAL ACTUATOR INTERFACE SYSTEM FOR ROBOTICSURGICAL TOOLS, U.S. Pat. No. 7,691,098, entitled PLATFORM LINK WRISTMECHANISM, U.S. Pat. No. 7,806,891, entitled REPOSITIONING ANDREORIENTATION OF MASTER/SLAVE RELATIONSHIP IN MINIMALLY INVASIVETELESURGERY, and U.S. Pat. No. 7,824,401, entitled ROBOTIC TOOL WITHWRISTED MONOPOLAR ELECTROSURGICAL END EFFECTORS. Many of such systems,however, have in the past been unable to generate the magnitude offorces required to effectively cut and fasten tissue.

FIG. 25 depicts one version of a master controller 1001 that may be usedin connection with a robotic arm slave cart 1100 of the type depicted inFIG. 26. Master controller 1001 and robotic arm slave cart 1100, as wellas their respective components and control systems are collectivelyreferred to herein as a robotic system 1000. Examples of such systemsand devices are disclosed in U.S. Pat. No. 7,524,320 which has beenherein incorporated by reference. Thus, various details of such deviceswill not be described in detail herein beyond that which may benecessary to understand various embodiments and forms of the presentinvention. As is known, the master controller 1001 generally includesmaster controllers (generally represented as 1003 in FIG. 25) which aregrasped by the surgeon and manipulated in space while the surgeon viewsthe procedure via a stereo display 1002. The master controllers 1001generally comprise manual input devices which preferably move withmultiple degrees of freedom, and which often further have an actuatablehandle for actuating tools (for example, for closing grasping saws,applying an electrical potential to an electrode, or the like).

As can be seen in FIG. 26, in one form, the robotic arm cart 1100 isconfigured to actuate a plurality of surgical tools, generallydesignated as 1200. Various robotic surgery systems and methodsemploying master controller and robotic arm cart arrangements aredisclosed in U.S. Pat. No. 6,132,368, entitled MULTI-COMPONENTTELEPRESENCE SYSTEM AND METHOD, the full disclosure of which isincorporated herein by reference. In various forms, the robotic arm cart1100 includes a base 1002 from which, in the illustrated embodiment,three surgical tools 1200 are supported. In various forms, the surgicaltools 1200 are each supported by a series of manually articulatablelinkages, generally referred to as set-up joints 1104, and a roboticmanipulator 1106. These structures are herein illustrated withprotective covers extending over much of the robotic linkage. Theseprotective covers may be optional, and may be limited in size orentirely eliminated in some embodiments to minimize the inertia that isencountered by the servo mechanisms used to manipulate such devices, tolimit the volume of moving components so as to avoid collisions, and tolimit the overall weight of the cart 1100. Cart 1100 will generally havedimensions suitable for transporting the cart 1100 between operatingrooms. The cart 1100 may be configured to typically fit through standardoperating room doors and onto standard hospital elevators. In variousforms, the cart 1100 would preferably have a weight and include a wheel(or other transportation) system that allows the cart 1100 to bepositioned adjacent an operating table by a single attendant.

Referring now to FIG. 27, in at least one form, robotic manipulators1106 may include a linkage 1108 that constrains movement of the surgicaltool 1200. In various embodiments, linkage 1108 includes rigid linkscoupled together by rotational joints in a parallelogram arrangement sothat the surgical tool 1200 rotates around a point in space 1110, asmore fully described in issued U.S. Pat. No. 5,817,084, the fulldisclosure of which is herein incorporated by reference. Theparallelogram arrangement constrains rotation to pivoting about an axis1112 a, sometimes called the pitch axis. The links supporting theparallelogram linkage are pivotally mounted to set-up joints 1104 (FIG.26) so that the surgical tool 1200 further rotates about an axis 1112 b,sometimes called the yaw axis. The pitch and yaw axes 1112 a, 1112 bintersect at the remote center 1114, which is aligned along a shaft 1208of the surgical tool 1200. The surgical tool 1200 may have furtherdegrees of driven freedom as supported by manipulator 1106, includingsliding motion of the surgical tool 1200 along the longitudinal toolaxis “LT-LT”. As the surgical tool 1200 slides along the tool axis LT-LTrelative to manipulator 1106 (arrow 1112 c), remote center 1114 remainsfixed relative to base 1116 of manipulator 1106. Hence, the entiremanipulator is generally moved to re-position remote center 1114.Linkage 1108 of manipulator 1106 is driven by a series of motors 1120.These motors actively move linkage 1108 in response to commands from aprocessor of a control system. As will be discussed in further detailbelow, motors 1120 are also employed to manipulate the surgical tool1200.

An alternative set-up joint structure is illustrated in FIG. 28. In thisembodiment, a surgical tool 1200 is supported by an alternativemanipulator structure 1106′ between two tissue manipulation tools. Thoseof ordinary skill in the art will appreciate that various embodiments ofthe present invention may incorporate a wide variety of alternativerobotic structures, including those described in U.S. Pat. No.5,878,193, entitled AUTOMATED ENDOSCOPE SYSTEM FOR OPTIMAL POSITIONING,the full disclosure of which is incorporated herein by reference.Additionally, while the data communication between a robotic componentand the processor of the robotic surgical system is primarily describedherein with reference to communication between the surgical tool 1200and the master controller 1001, it should be understood that similarcommunication may take place between circuitry of a manipulator, aset-up joint, an endoscope or other image capture device, or the like,and the processor of the robotic surgical system for componentcompatibility verification, component-type identification, componentcalibration (such as off-set or the like) communication, confirmation ofcoupling of the component to the robotic surgical system, or the like.

An exemplary non-limiting surgical tool 1200 that is well-adapted foruse with a robotic system 1000 that has a tool drive assembly 1010 (FIG.30) that is operatively coupled to a master controller 1001 that isoperable by inputs from an operator (i.e., a surgeon) is depicted inFIG. 29. As can be seen in that Figure, the surgical tool 1200 includesa surgical end effector 2012 that comprises an endocutter. In at leastone form, the surgical tool 1200 generally includes an elongated shaftassembly 2008 that has a proximal closure tube 2040 and a distal closuretube 2042 that are coupled together by an articulation joint 2011. Thesurgical tool 1200 is operably coupled to the manipulator by a toolmounting portion, generally designated as 1300. The surgical tool 1200further includes an interface 1230 which mechanically and electricallycouples the tool mounting portion 1300 to the manipulator. One form ofinterface 1230 is illustrated in FIGS. 27-31. In various embodiments,the tool mounting portion 1300 includes a tool mounting plate 1302 thatoperably supports a plurality of (four are shown in FIG. 34) rotatablebody portions, driven discs or elements 1304, that each include a pairof pins 1306 that extend from a surface of the driven element 1304. Onepin 1306 is closer to an axis of rotation of each driven elements 1304than the other pin 1306 on the same driven element 1304, which helps toensure positive angular alignment of the driven element 1304. Interface1230 includes an adaptor portion 1240 that is configured to mountinglyengage the mounting plate 1302 as will be further discussed below. Theadaptor portion 1240 may include an array of electrical connecting pins1242 (FIG. 32) which may be coupled to a memory structure by a circuitboard within the tool mounting portion 1300. While interface 1230 isdescribed herein with reference to mechanical, electrical, and magneticcoupling elements, it should be understood that a wide variety oftelemetry modalities might be used, including infrared, inductivecoupling, or the like.

As can be seen in FIGS. 30-33, the adapter portion 1240 generallyincludes a tool side 1244 and a holder side 1246. In various forms, aplurality of rotatable bodies 1250 are mounted to a floating plate 1248which has a limited range of movement relative to the surroundingadaptor structure normal to the major surfaces of the adaptor 1240.Axial movement of the floating plate 1248 helps decouple the rotatablebodies 1250 from the tool mounting portion 1300 when the levers 1303along the sides of the tool mounting portion housing 1301 are actuated(See FIG. 29). Other mechanisms/arrangements may be employed forreleasably coupling the tool mounting portion 1300 to the adaptor 1240.In at least one form, rotatable bodies 1250 are resiliently mounted tofloating plate 1248 by resilient radial members which extend into acircumferential indentation about the rotatable bodies 1250. Therotatable bodies 1250 can move axially relative to plate 1248 bydeflection of these resilient structures. When disposed in a first axialposition (toward tool side 1244) the rotatable bodies 1250 are free torotate without angular limitation. However, as the rotatable bodies 1250move axially toward tool side 1244, tabs 1252 (extending radially fromthe rotatable bodies 1250) laterally engage detents on the floatingplates so as to limit angular rotation of the rotatable bodies 1250about their axes. This limited rotation can be used to help drivinglyengage the rotatable bodies 1250 with drive pins 1272 of a correspondingtool holder portion 1270 of the robotic system 1000, as the drive pins1272 will push the rotatable bodies 1250 into the limited rotationposition until the pins 1234 are aligned with (and slide into) openings1256′. Openings 1256 on the tool side 1244 and openings 1256′ on theholder side 1246 of rotatable bodies 1250 are configured to accuratelyalign the driven elements 1304 (FIG. 34) of the tool mounting portion1300 with the drive elements 1271 of the tool holder 1270. As describedabove regarding inner and outer pins 1306 of driven elements 1304, theopenings 1256, 1256′ are at differing distances from the axis ofrotation on their respective rotatable bodies 1250 so as to ensure thatthe alignment is not 180 degrees from its intended position.Additionally, each of the openings 1256 is slightly radially elongatedso as to fittingly receive the pins 1306 in the circumferentialorientation. This allows the pins 1306 to slide radially within theopenings 1256, 1256′ and accommodate some axial misalignment between thetool 1200 and tool holder 1270, while minimizing any angularmisalignment and backlash between the drive and driven elements.Openings 1256 on the tool side 1244 are offset by about 90 degrees fromthe openings 1256′ (shown in broken lines) on the holder side 1246, ascan be seen most clearly in FIG. 33.

Various embodiments may further include an array of electrical connectorpins 1242 located on holder side 1246 of adaptor 1240, and the tool side1244 of the adaptor 1240 may include slots 1258 (FIG. 33) for receivinga pin array (not shown) from the tool mounting portion 1300. In additionto transmitting electrical signals between the surgical tool 1200 andthe tool holder 1270, at least some of these electrical connections maybe coupled to an adaptor memory device 1260 (FIG. 32) by a circuit boardof the adaptor 1240.

A detachable latch arrangement 1239 may be employed to releasably affixthe adaptor 1240 to the tool holder 1270. As used herein, the term “tooldrive assembly” when used in the context of the robotic system 1000, atleast encompasses various embodiments of the adapter 1240 and toolholder 1270 and which has been generally designated as 1010 in FIG. 30.For example, as can be seen in FIG. 30, the tool holder 1270 may includea first latch pin arrangement 1274 that is sized to be received incorresponding clevis slots 1241 provided in the adaptor 1240. Inaddition, the tool holder 1270 may further have second latch pins 1276that are sized to be retained in corresponding latch clevises 1243 inthe adaptor 1240. See FIG. 32. In at least one form, a latch assembly1245 is movably supported on the adapter 1240 and is biasable between afirst latched position wherein the latch pins 1276 are retained withintheir respective latch clevis 1243 and an unlatched position wherein thesecond latch pins 1276 may be into or removed from the latch clevises1243. A spring or springs (not shown) are employed to bias the latchassembly into the latched position. A lip on the tool side 1244 ofadaptor 1240 may slidably receive laterally extending tabs of toolmounting housing 1301.

Turning next to FIGS. 34-41, in at least one embodiment, the surgicaltool 1200 includes a surgical end effector 2012 that comprises in thisexample, among other things, at least one component 2024 that isselectively movable between first and second positions relative to atleast one other component 2022 in response to various control motionsapplied thereto as will be discussed in further detail below. In variousembodiments, component 2022 comprises an elongated channel 2022configured to operably support a surgical staple cartridge 2034 thereinand component 2024 comprises a pivotally translatable clamping member,such as an anvil 2024. Various embodiments of the surgical end effector2012 are configured to maintain the anvil 2024 and elongated channel2022 at a spacing that assures effective stapling and severing of tissueclamped in the surgical end effector 2012. As can be seen in FIG. 40,the surgical end effector 2012 further includes a cutting instrument2032 and a sled 2033. The cutting instrument 2032 may be, for example, aknife. The surgical staple cartridge 2034 operably houses a plurality ofsurgical staples (not show) therein that are supported on movable stapledrivers (not shown). As the cutting instrument 2032 is driven distallythrough a centrally-disposed slot (not shown) in the surgical staplecartridge 2034, it forces the sled 2033 distally as well. As the sled2033 is driven distally, its “wedge-shaped” configuration contacts themovable staple drivers and drives them vertically toward the closedanvil 2024. The surgical staples are formed as they are driven into theforming surface located on the underside of the anvil 2024. The sled2033 may be part of the surgical staple cartridge 2034, such that whenthe cutting instrument 2032 is retracted following the cuttingoperation, the sled 2033 does not retract. The anvil 2024 may bepivotably opened and closed at a pivot point 2025 located at theproximal end of the elongated channel 2022. The anvil 2024 may alsoinclude a tab 2027 at its proximal end that interacts with a componentof the mechanical closure system (described further below) to facilitatethe opening of the anvil 2024. The elongated channel 2022 and the anvil2024 may be made of an electrically conductive material (such as metal)so that they may serve as part of an antenna that communicates withsensor(s) in the end effector, as described above. The surgical staplecartridge 2034 could be made of a nonconductive material (such asplastic) and the sensor may be connected to or disposed in the surgicalstaple cartridge 2034, as was also described above.

As can be seen in FIGS. 34-41, the surgical end effector 2012 isattached to the tool mounting portion 1300 by an elongated shaftassembly 2008 according to various embodiments. As shown in theillustrated embodiment, the shaft assembly 2008 includes an articulationjoint generally indicated as 2011 that enables the surgical end effector2012 to be selectively articulated about an articulation axis AA-AA thatis substantially transverse to a longitudinal tool axis LT-LT. See FIG.35. In other embodiments, the articulation joint is omitted. In variousembodiments, the shaft assembly 2008 may include a closure tube assembly2009 that comprises a proximal closure tube 2040 and a distal closuretube 2042 that are pivotably linked by a pivot links 2044 and operablysupported on a spine assembly generally depicted as 2049. In theillustrated embodiment, the spine assembly 2049 comprises a distal spineportion 2050 that is attached to the elongated channel 2022 and ispivotally coupled to the proximal spine portion 2052. The closure tubeassembly 2009 is configured to axially slide on the spine assembly 2049in response to actuation motions applied thereto. The distal closuretube 2042 includes an opening 2045 into which the tab 2027 on the anvil2024 is inserted in order to facilitate opening of the anvil 2024 as thedistal closure tube 2042 is moved axially in the proximal direction“PD”. The closure tubes 2040, 2042 may be made of electricallyconductive material (such as metal) so that they may serve as part ofthe antenna, as described above. Components of the main drive shaftassembly (e.g., the drive shafts 2048, 2050) may be made of anonconductive material (such as plastic).

In use, it may be desirable to rotate the surgical end effector 2012about the longitudinal tool axis LT-LT. In at least one embodiment, thetool mounting portion 1300 includes a rotational transmission assembly2069 that is configured to receive a corresponding rotary output motionfrom the tool drive assembly 1010 of the robotic system 1000 and convertthat rotary output motion to a rotary control motion for rotating theelongated shaft assembly 2008 (and surgical end effector 2012) about thelongitudinal tool axis LT-LT. In various embodiments, for example, theproximal end 2060 of the proximal closure tube 2040 is rotatablysupported on the tool mounting plate 1302 of the tool mounting portion1300 by a forward support cradle 1309 and a closure sled 2100 that isalso movably supported on the tool mounting plate 1302. In at least oneform, the rotational transmission assembly 2069 includes a tube gearsegment 2062 that is formed on (or attached to) the proximal end 2060 ofthe proximal closure tube 2040 for operable engagement by a rotationalgear assembly 2070 that is operably supported on the tool mounting plate1302. As can be seen in FIG. 37, the rotational gear assembly 2070, inat least one embodiment, comprises a rotation drive gear 2072 that iscoupled to a corresponding first one of the driven discs or elements1304 on the adapter side 1307 of the tool mounting plate 1302 when thetool mounting portion 1300 is coupled to the tool drive assembly 1010.See FIG. 34. The rotational gear assembly 2070 further comprises arotary driven gear 2074 that is rotatably supported on the tool mountingplate 1302 in meshing engagement with the tube gear segment 2062 and therotation drive gear 2072. Application of a first rotary output motionfrom the tool drive assembly 1010 of the robotic system 1000 to thecorresponding driven element 1304 will thereby cause rotation of therotation drive gear 2072. Rotation of the rotation drive gear 2072ultimately results in the rotation of the elongated shaft assembly 2008(and the surgical end effector 2012) about the longitudinal tool axisLT-LT (represented by arrow “R” in FIG. 37). It will be appreciated thatthe application of a rotary output motion from the tool drive assembly1010 in one direction will result in the rotation of the elongated shaftassembly 2008 and surgical end effector 2012 about the longitudinal toolaxis LT-LT in a first direction and an application of the rotary outputmotion in an opposite direction will result in the rotation of theelongated shaft assembly 2008 and surgical end effector 2012 in a seconddirection that is opposite to the first direction.

In at least one embodiment, the closure of the anvil 2024 relative tothe staple cartridge 2034 is accomplished by axially moving the closuretube assembly 2009 in the distal direction “DD” on the spine assembly2049. As indicated above, in various embodiments, the proximal end 2060of the proximal closure tube 2040 is supported by the closure sled 2100which comprises a portion of a closure transmission, generally depictedas 2099. In at least one form, the closure sled 2100 is configured tosupport the closure tube 2009 on the tool mounting plate 1320 such thatthe proximal closure tube 2040 can rotate relative to the closure sled2100, yet travel axially with the closure sled 2100. In particular, ascan be seen in FIG. 41, the closure sled 2100 has an upstanding tab 2101that extends into a radial groove 2063 in the proximal end portion ofthe proximal closure tube 2040. In addition, as can be seen in FIGS. 39and 42, the closure sled 2100 has a tab portion 2102 that extendsthrough a slot 1305 in the tool mounting plate 1302. The tab portion2102 is configured to retain the closure sled 2100 in sliding engagementwith the tool mounting plate 1302. In various embodiments, the closuresled 2100 has an upstanding portion 2104 that has a closure rack gear2106 formed thereon. The closure rack gear 2106 is configured fordriving engagement with a closure gear assembly 2110. See FIG. 39.

In various forms, the closure gear assembly 2110 includes a closure spurgear 2112 that is coupled to a corresponding second one of the drivendiscs or elements 1304 on the adapter side 1307 of the tool mountingplate 1302. See FIG. 34. Thus, application of a second rotary outputmotion from the tool drive assembly 1010 of the robotic system 1000 tothe corresponding second driven element 1304 will cause rotation of theclosure spur gear 2112 when the tool mounting portion 1300 is coupled tothe tool drive assembly 1010. The closure gear assembly 2110 furtherincludes a closure reduction gear set 2114 that is supported in meshingengagement with the closure spur gear 2112. As can be seen in FIGS. 38and 39, the closure reduction gear set 2114 includes a driven gear 2116that is rotatably supported in meshing engagement with the closure spurgear 2112. The closure reduction gear set 2114 further includes a firstclosure drive gear 2118 that is in meshing engagement with a secondclosure drive gear 2120 that is rotatably supported on the tool mountingplate 1302 in meshing engagement with the closure rack gear 2106. Thus,application of a second rotary output motion from the tool driveassembly 1010 of the robotic system 1000 to the corresponding seconddriven element 1304 will cause rotation of the closure spur gear 2112and the closure transmission 2110 and ultimately drive the closure sled2100 and closure tube assembly 2009 axially. The axial direction inwhich the closure tube assembly 2009 moves ultimately depends upon thedirection in which the second driven element 1304 is rotated. Forexample, in response to one rotary output motion received from the tooldrive assembly 1010 of the robotic system 1000, the closure sled 2100will be driven in the distal direction “DD” and ultimately drive theclosure tube assembly 1009 in the distal direction. As the distalclosure tube 2042 is driven distally, the end of the closure tubesegment 2042 will engage a portion of the anvil 2024 and cause the anvil2024 to pivot to a closed position. Upon application of an “opening” output motion from the tool drive assembly 1010 of the robotic system 1000,the closure sled 2100 and shaft assembly 2008 will be driven in theproximal direction “PD”. As the distal closure tube 2042 is driven inthe proximal direction, the opening 2045 therein interacts with the tab2027 on the anvil 2024 to facilitate the opening thereof. In variousembodiments, a spring (not shown) may be employed to bias the anvil tothe open position when the distal closure tube 2042 has been moved toits starting position. In various embodiments, the various gears of theclosure gear assembly 2110 are sized to generate the necessary closureforces needed to satisfactorily close the anvil 2024 onto the tissue tobe cut and stapled by the surgical end effector 2012. For example, thegears of the closure transmission 2110 may be sized to generateapproximately 70-120 pounds.

In various embodiments, the cutting instrument 2032 is driven throughthe surgical end effector 2012 by a knife bar 2200. See FIGS. 40 and 42.In at least one form, the knife bar 2200 may be fabricated from, forexample, stainless steel or other similar material and has asubstantially rectangular cross-sectional shape. Such knife barconfiguration is sufficiently rigid to push the cutting instrument 2032through tissue clamped in the surgical end effector 2012, while stillbeing flexible enough to enable the surgical end effector 2012 toarticulate relative to the proximal closure tube 2040 and the proximalspine portion 2052 about the articulation axis AA-AA as will bediscussed in further detail below. As can be seen in FIGS. 43 and 44,the proximal spine portion 2052 has a rectangular-shaped passage 2054extending therethrough to provide support to the knife bar 2200 as it isaxially pushed therethrough. The proximal spine portion 2052 has aproximal end 2056 that is rotatably mounted to a spine mounting bracket2057 attached to the tool mounting plate 1032. See FIG. 42. Sucharrangement permits the proximal spine portion 2052 to rotate, but notmove axially, within the proximal closure tube 2040.

As shown in FIG. 40, the distal end 2202 of the knife bar 2200 isattached to the cutting instrument 2032. The proximal end 2204 of theknife bar 2200 is rotatably affixed to a knife rack gear 2206 such thatthe knife bar 2200 is free to rotate relative to the knife rack gear2206. See FIG. 39. As can be seen in FIGS. 36-41, the knife rack gear2206 is slidably supported within a rack housing 2210 that is attachedto the tool mounting plate 1302 such that the knife rack gear 2206 isretained in meshing engagement with a knife gear assembly 2220. Morespecifically and with reference to FIG. 39, in at least one embodiment,the knife gear assembly 2220 includes a knife spur gear 2222 that iscoupled to a corresponding third one of the driven discs or elements1304 on the adapter side 1307 of the tool mounting plate 1302. See FIG.34. Thus, application of another rotary output motion from the roboticsystem 1000 through the tool drive assembly 1010 to the correspondingthird driven element 1304 will cause rotation of the knife spur gear2222. The knife gear assembly 2220 further includes a knife gearreduction set 2224 that includes a first knife driven gear 2226 and asecond knife drive gear 2228. The knife gear reduction set 2224 isrotatably mounted to the tool mounting plate 1302 such that the firstknife driven gear 2226 is in meshing engagement with the knife spur gear2222. Likewise, the second knife drive gear 2228 is in meshingengagement with a third knife drive gear 2230 that is rotatablysupported on the tool mounting plate 1302 in meshing engagement with theknife rack gear 2206. In various embodiments, the gears of the knifegear assembly 2220 are sized to generate the forces needed to drive thecutting element 2032 through the tissue clamped in the surgical endeffector 2012 and actuate the staples therein. For example, the gears ofthe knife drive assembly 2230 may be sized to generate approximately 40to 100 pounds. It will be appreciated that the application of a rotaryoutput motion from the tool drive assembly 1010 in one direction willresult in the axial movement of the cutting instrument 2032 in a distaldirection and application of the rotary output motion in an oppositedirection will result in the axial travel of the cutting instrument 2032in a proximal direction.

In various embodiments, the surgical tool 1200 employs and articulationsystem 2007 that includes an articulation joint 2011 that enables thesurgical end effector 2012 to be articulated about an articulation axisAA-AA that is substantially transverse to the longitudinal tool axisLT-LT. In at least one embodiment, the surgical tool 1200 includes firstand second articulation bars 2250 a, 2250 b that are slidably supportedwithin corresponding passages 2053 provided through the proximal spineportion 2052. See FIGS. 42 and 44. In at least one form, the first andsecond articulation bars 2250 a, 2250 b are actuated by an articulationtransmission generally designated as 2249 that is operably supported onthe tool mounting plate 1032. Each of the articulation bars 2250 a, 2250b has a proximal end 2252 that has a guide rod protruding therefromwhich extend laterally through a corresponding slot in the proximal endportion of the proximal spine portion 2052 and into a correspondingarcuate slot in an articulation nut 2260 which comprises a portion ofthe articulation transmission. FIG. 43 illustrates articulation bar 2250a. It will be understood that articulation bar 2250 b is similarlyconstructed. As can be seen in FIG. 40, for example, the articulationbar 2250 a has a guide rod 2254 which extends laterally through acorresponding slot 2058 in the proximal end portion 2056 of the distalspine portion 2050 and into a corresponding arcuate slot 2262 in thearticulation nut 2260. In addition, the articulation bar 2250 a has adistal end 2251 a that is pivotally coupled to the distal spine portion2050 by, for example, a pin 2253 a and articulation bar 2250 b has adistal end 2251 b that is pivotally coupled to the distal spine portion2050 by, for example, a pin 2253 b. In particular, the articulation bar2250 a is laterally offset in a first lateral direction from thelongitudinal tool axis LT-LT and the articulation bar 2250 b islaterally offset in a second lateral direction from the longitudinaltool axis LT-LT. Thus, axial movement of the articulation bars 2250 aand 2250 b in opposing directions will result in the articulation of thedistal spine portion 2050 as well as the surgical end effector 2012attached thereto about the articulation axis AA-AA as will be discussedin further detail below.

Articulation of the surgical end effector 2012 is controlled by rotatingthe articulation nut 2260 about the longitudinal tool axis LT-LT. Thearticulation nut 2260 is rotatably journaled on the proximal end portion2056 of the distal spine portion 2050 and is rotatably driven thereon byan articulation gear assembly 2270. More specifically and with referenceto FIG. 37, in at least one embodiment, the articulation gear assembly2270 includes an articulation spur gear 2272 that is coupled to acorresponding fourth one of the driven discs or elements 1304 on theadapter side 1307 of the tool mounting plate 1302. See FIG. 34. Thus,application of another rotary input motion from the robotic system 1000through the tool drive assembly 1010 to the corresponding fourth drivenelement 1304 will cause rotation of the articulation spur gear 2272 whenthe interface 1230 is coupled to the tool holder 1270. An articulationdrive gear 2274 is rotatably supported on the tool mounting plate 1302in meshing engagement with the articulation spur gear 2272 and a gearportion 2264 of the articulation nut 2260 as shown. As can be seen inFIGS. 42 and 43, the articulation nut 2260 has a shoulder 2266 formedthereon that defines an annular groove 2267 for receiving retainingposts 2268 therein. Retaining posts 2268 are attached to the toolmounting plate 1302 and serve to prevent the articulation nut 2260 frommoving axially on the proximal spine portion 2052 while maintaining theability to be rotated relative thereto. Thus, rotation of thearticulation nut 2260 in a first direction, will result in the axialmovement of the articulation bar 2250 a in a distal direction “DD” andthe axial movement of the articulation bar 2250 b in a proximaldirection “PD” because of the interaction of the guide rods 2254 withthe spiral slots 2262 in the articulation gear 2260. Similarly, rotationof the articulation nut 2260 in a second direction that is opposite tothe first direction will result in the axial movement of thearticulation bar 2250 a in the proximal direction “PD” as well as causearticulation bar 2250 b to axially move in the distal direction “DD”.Thus, the surgical end effector 2012 may be selectively articulatedabout articulation axis “AA-AA” in a first direction “FD” bysimultaneously moving the articulation bar 2250 a in the distaldirection “DD” and the articulation bar 2250 b in the proximal direction“PD”. Likewise, the surgical end effector 2012 may be selectivelyarticulated about the articulation axis “AA-AA” in a second direction“SD” by simultaneously moving the articulation bar 2250 a in theproximal direction “PD” and the articulation bar 2250 b in the distaldirection “DD.” See FIG. 35.

The tool embodiment described above employs an interface arrangementthat is particularly well-suited for mounting the roboticallycontrollable medical tool onto at least one form of robotic armarrangement that generates at least four different rotary controlmotions. Those of ordinary skill in the art will appreciate that suchrotary output motions may be selectively controlled through theprogrammable control systems employed by the robotic system/controller.For example, the tool arrangement described above may be well-suited foruse with those robotic systems manufactured by Intuitive Surgical, Inc.of Sunnyvale, Calif., U.S.A., many of which may be described in detailin various patents incorporated herein by reference. The unique andnovel aspects of various embodiments of the present invention serve toutilize the rotary output motions supplied by the robotic system togenerate specific control motions having sufficient magnitudes thatenable end effectors to cut and staple tissue. Thus, the uniquearrangements and principles of various embodiments of the presentinvention may enable a variety of different forms of the tool systemsdisclosed and claimed herein to be effectively employed in connectionwith other types and forms of robotic systems that supply programmedrotary or other output motions. In addition, as will become furtherapparent as the present Detailed Description proceeds, various endeffector embodiments of the present invention that require other formsof actuation motions may also be effectively actuated utilizing one ormore of the control motions generated by the robotic system.

FIGS. 46-50 illustrate yet another surgical tool 2300 that may beeffectively employed in connection with the robotic system 1000 that hasa tool drive assembly that is operably coupled to a controller of therobotic system that is operable by inputs from an operator and which isconfigured to provide at least one rotary output motion to at least onerotatable body portion supported on the tool drive assembly. In variousforms, the surgical tool 2300 includes a surgical end effector 2312 thatincludes an elongated channel 2322 and a pivotally translatable clampingmember, such as an anvil 2324, which are maintained at a spacing thatassures effective stapling and severing of tissue clamped in thesurgical end effector 2312. As shown in the illustrated embodiment, thesurgical end effector 2312 may include, in addition to thepreviously-mentioned elongated channel 2322 and anvil 2324, a cuttinginstrument 2332 that has a sled portion 2333 formed thereon, a surgicalstaple cartridge 2334 that is seated in the elongated channel 2322, anda rotary end effector drive shaft 2336 that has a helical screw threadformed thereon. The cutting instrument 2332 may be, for example, aknife. As will be discussed in further detail below, rotation of the endeffector drive shaft 2336 will cause the cutting instrument 2332 andsled portion 2333 to axially travel through the surgical staplecartridge 2334 to move between a starting position and an endingposition. The direction of axial travel of the cutting instrument 2332depends upon the direction in which the end effector drive shaft 2336 isrotated. The anvil 2324 may be pivotably opened and closed at a pivotpoint 2325 connected to the proximate end of the elongated channel 2322.The anvil 2324 may also include a tab 2327 at its proximate end thatoperably interfaces with a component of the mechanical closure system(described further below) to open and close the anvil 2324. When the endeffector drive shaft 2336 is rotated, the cutting instrument 2332 andsled 2333 will travel longitudinally through the surgical staplecartridge 2334 from the starting position to the ending position,thereby cutting tissue clamped within the surgical end effector 2312.The movement of the sled 2333 through the surgical staple cartridge 2334causes the staples therein to be driven through the severed tissue andagainst the closed anvil 2324, which turns the staples to fasten thesevered tissue. In one form, the elongated channel 2322 and the anvil2324 may be made of an electrically conductive material (such as metal)so that they may serve as part of the antenna that communicates withsensor(s) in the end effector, as described above. The surgical staplecartridge 2334 could be made of a nonconductive material (such asplastic) and the sensor may be connected to or disposed in the surgicalstaple cartridge 2334, as described above.

It should be noted that although the embodiments of the surgical tool2300 described herein employ a surgical end effector 2312 that staplesthe severed tissue, in other embodiments different techniques forfastening or sealing the severed tissue may be used. For example, endeffectors that use RF energy or adhesives to fasten the severed tissuemay also be used. U.S. Pat. No. 5,709,680, entitled ELECTROSURGICALHEMOSTATIC DEVICE to Yates et al., and U.S. Pat. No. 5,688,270, entitledELECTROSURGICAL HEMOSTATIC DEVICE WITH RECESSED AND/OR OFFSET ELECTRODESto Yates et al., which are incorporated herein by reference, disclosecutting instruments that use RF energy to fasten the severed tissue.U.S. patent application Ser. No. 11/267,811 to Morgan et al., now U.S.Pat. No. 7,673,783, and U.S. patent application Ser. No. 11/267,383 toShelton et al., now U.S. Pat. No. 7,607,557, which are also incorporatedherein by reference, disclose cutting instruments that use adhesives tofasten the severed tissue. Accordingly, although the description hereinrefers to cutting/stapling operations and the like, it should berecognized that this is an exemplary embodiment and is not meant to belimiting. Other tissue-fastening techniques may also be used.

In the illustrated embodiment, the surgical end effector 2312 is coupledto an elongated shaft assembly 2308 that is coupled to a tool mountingportion 2460 and defines a longitudinal tool axis LT-LT. In thisembodiment, the elongated shaft assembly 2308 does not include anarticulation joint. Those of ordinary skill in the art will understandthat other embodiments may have an articulation joint therein. In atleast one embodiment, the elongated shaft assembly 2308 comprises ahollow outer tube 2340 that is rotatably supported on a tool mountingplate 2462 of a tool mounting portion 2460 as will be discussed infurther detail below. In various embodiments, the elongated shaftassembly 2308 further includes a distal spine shaft 2350. Distal spineshaft 2350 has a distal end portion 2354 that is coupled to, orotherwise integrally formed with, a distal stationary base portion 2360that is non-movably coupled to the channel 2322. See FIGS. 47-49.

As shown in FIG. 47, the distal spine shaft 2350 has a proximal endportion 2351 that is slidably received within a slot 2355 in a proximalspine shaft 2353 that is non-movably supported within the hollow outertube 2340 by at least one support collar 2357. As can be further seen inFIGS. 47 and 48, the surgical tool 2300 includes a closure tube 2370that is constrained to only move axially relative to the distalstationary base portion 2360. The closure tube 2370 has a proximal end2372 that has an internal thread 2374 formed therein that is in threadedengagement with a transmission arrangement, generally depicted as 2375that is operably supported on the tool mounting plate 2462. In variousforms, the transmission arrangement 2375 includes a rotary drive shaftassembly, generally designated as 2381. When rotated, the rotary driveshaft assembly 2381 will cause the closure tube 2370 to move axially aswill be describe in further detail below. In at least one form, therotary drive shaft assembly 2381 includes a closure drive nut 2382 of aclosure clutch assembly generally designated as 2380. More specifically,the closure drive nut 2382 has a proximal end portion 2384 that isrotatably supported relative to the outer tube 2340 and is in threadedengagement with the closure tube 2370. For assembly purposes, theproximal end portion 2384 may be threadably attached to a retention ring2386. Retention ring 2386, in cooperation with an end 2387 of theclosure drive nut 2382, defines an annular slot 2388 into which ashoulder 2392 of a locking collar 2390 extends. The locking collar 2390is non-movably attached (e.g., welded, glued, etc.) to the end of theouter tube 2340. Such arrangement serves to affix the closure drive nut2382 to the outer tube 2340 while enabling the closure drive nut 2382 torotate relative to the outer tube 2340. The closure drive nut 2382further has a distal end 2383 that has a threaded portion 2385 thatthreadably engages the internal thread 2374 of the closure tube 2370.Thus, rotation of the closure drive nut 2382 will cause the closure tube2370 to move axially as represented by arrow “D” in FIG. 48.

Closure of the anvil 2324 and actuation of the cutting instrument 2332are accomplished by control motions that are transmitted by a hollowdrive sleeve 2400. As can be seen in FIGS. 47 and 48, the hollow drivesleeve 2400 is rotatably and slidably received on the distal spine shaft2350. The drive sleeve 2400 has a proximal end portion 2401 that isrotatably mounted to the proximal spine shaft 2353 that protrudes fromthe tool mounting portion 2460 such that the drive sleeve 2400 mayrotate relative thereto. See FIG. 47. As can also be seen in FIGS.47-49, the drive sleeve 2400 is rotated about the longitudinal tool axis“LT-LT” by a drive shaft 2440. The drive shaft 2440 has a drive gear2444 that is attached to its distal end 2442 and is in meshingengagement with a driven gear 2450 that is attached to the drive sleeve2400.

The drive sleeve 2400 further has a distal end portion 2402 that iscoupled to a closure clutch 2410 portion of the closure clutch assembly2380 that has a proximal face 2412 and a distal face 2414. The proximalface 2412 has a series of proximal teeth 2416 formed thereon that areadapted for selective engagement with corresponding proximal teethcavities 2418 formed in the proximal end portion 2384 of the closuredrive nut 2382. Thus, when the proximal teeth 2416 are in meshingengagement with the proximal teeth cavities 2418 in the closure drivenut 2382, rotation of the drive sleeve 2400 will result in rotation ofthe closure drive nut 2382 and ultimately cause the closure tube 2370 tomove axially as will be discussed in further detail below.

As can be most particularly seen in FIGS. 47 and 48, the distal face2414 of the drive clutch portion 2410 has a series of distal teeth 2415formed thereon that are adapted for selective engagement withcorresponding distal teeth cavities 2426 formed in a face plate portion2424 of a knife drive shaft assembly 2420. In various embodiments, theknife drive shaft assembly 2420 comprises a hollow knife shaft segment2430 that is rotatably received on a corresponding portion of the distalspine shaft 2350 that is attached to or protrudes from the stationarybase 2360. When the distal teeth 2415 of the closure clutch portion 2410are in meshing engagement with the distal teeth cavities 2426 in theface plate portion 2424, rotation of the drive sleeve 2400 will resultin rotation of the drive shaft segment 2430 about the stationary shaft2350. As can be seen in FIGS. 47-49, a knife drive gear 2432 is attachedto the drive shaft segment 2430 and is meshing engagement with a driveknife gear 2434 that is attached to the end effector drive shaft 2336.Thus, rotation of the drive shaft segment 2430 will result in therotation of the end effector drive shaft 2336 to drive the cuttinginstrument 2332 and sled 2333 distally through the surgical staplecartridge 2334 to cut and staple tissue clamped within the surgical endeffector 2312. The sled 2333 may be made of, for example, plastic, andmay have a sloped distal surface. As the sled 2333 traverses theelongated channel 2322, the sloped forward surface of the sled 2333pushes up or “drive” the staples in the surgical staple cartridge 2334through the clamped tissue and against the anvil 2324. The anvil 2324turns or “forms” the staples, thereby stapling the severed tissue. Asused herein, the term “fire” refers to the initiation of actionsrequired to drive the cutting instrument and sled portion in a distaldirection through the surgical staple cartridge to cut the tissueclamped in the surgical end effector and drive the staples through thesevered tissue.

In use, it may be desirable to rotate the surgical end effector 2312about the longitudinal tool axis LT-LT. In at least one embodiment, thetransmission arrangement 2375 includes a rotational transmissionassembly 2465 that is configured to receive a corresponding rotaryoutput motion from the tool drive assembly 1010 of the robotic system1000 and convert that rotary output motion to a rotary control motionfor rotating the elongated shaft assembly 2308 (and surgical endeffector 2312) about the longitudinal tool axis LT-LT. As can be seen inFIG. 50, a proximal end 2341 of the outer tube 2340 is rotatablysupported within a cradle arrangement 2343 attached to the tool mountingplate 2462 of the tool mounting portion 2460. A rotation gear 2345 isformed on or attached to the proximal end 2341 of the outer tube 2340 ofthe elongated shaft assembly 2308 for meshing engagement with a rotationgear assembly 2470 operably supported on the tool mounting plate 2462.In at least one embodiment, a rotation drive gear 2472 is coupled to acorresponding first one of the driven discs or elements 1304 on theadapter side of the tool mounting plate 2462 when the tool mountingportion 2460 is coupled to the tool drive assembly 1010. See FIGS. 34and 50. The rotation drive assembly 2470 further comprises a rotarydriven gear 2474 that is rotatably supported on the tool mounting plate2462 in meshing engagement with the rotation gear 2345 and the rotationdrive gear 2472. Application of a first rotary output motion from therobotic system 1000 through the tool drive assembly 1010 to thecorresponding driven element 1304 will thereby cause rotation of therotation drive gear 2472 by virtue of being operably coupled thereto.Rotation of the rotation drive gear 2472 ultimately results in therotation of the elongated shaft assembly 2308 (and the end effector2312) about the longitudinal tool axis LT-LT (primary rotary motion).

Closure of the anvil 2324 relative to the staple cartridge 2034 isaccomplished by axially moving the closure tube 2370 in the distaldirection “DD”. Axial movement of the closure tube 2370 in the distaldirection “DD” is accomplished by applying a rotary control motion tothe closure drive nut 2382. To apply the rotary control motion to theclosure drive nut 2382, the closure clutch 2410 must first be broughtinto meshing engagement with the proximal end portion 2384 of theclosure drive nut 2382. In various embodiments, the transmissionarrangement 2375 further includes a shifter drive assembly 2480 that isoperably supported on the tool mounting plate 2462. More specificallyand with reference to FIG. 50, it can be seen that a proximal endportion 2359 of the proximal spine portion 2353 extends through therotation gear 2345 and is rotatably coupled to a shifter gear rack 2481that is slidably affixed to the tool mounting plate 2462 through slots2482. The shifter drive assembly 2480 further comprises a shifter drivegear 2483 that is coupled to a corresponding second one of the drivendiscs or elements 1304 on the adapter side of the tool mounting plate2462 when the tool mounting portion 2460 is coupled to the tool holder1270. See FIGS. 34 and 50. The shifter drive assembly 2480 furthercomprises a shifter driven gear 2478 that is rotatably supported on thetool mounting plate 2462 in meshing engagement with the shifter drivegear 2483 and the shifter rack gear 2482. Application of a second rotaryoutput motion from the robotic system 1000 through the tool driveassembly 1010 to the corresponding driven element 1304 will therebycause rotation of the shifter drive gear 2483 by virtue of beingoperably coupled thereto. Rotation of the shifter drive gear 2483ultimately results in the axial movement of the shifter gear rack 2482and the proximal spine portion 2353 as well as the drive sleeve 2400 andthe closure clutch 2410 attached thereto. The direction of axial travelof the closure clutch 2410 depends upon the direction in which theshifter drive gear 2483 is rotated by the robotic system 1000. Thus,rotation of the shifter drive gear 2483 in a first rotary direction willresult in the axial movement of the closure clutch 2410 in the proximaldirection “PD” to bring the proximal teeth 2416 into meshing engagementwith the proximal teeth cavities 2418 in the closure drive nut 2382.Conversely, rotation of the shifter drive gear 2483 in a second rotarydirection (opposite to the first rotary direction) will result in theaxial movement of the closure clutch 2410 in the distal direction “DD”to bring the distal teeth 2415 into meshing engagement withcorresponding distal teeth cavities 2426 formed in the face plateportion 2424 of the knife drive shaft assembly 2420.

Once the closure clutch 2410 has been brought into meshing engagementwith the closure drive nut 2382, the closure drive nut 2382 is rotatedby rotating the closure clutch 2410. Rotation of the closure clutch 2410is controlled by applying rotary output motions to a rotary drivetransmission portion 2490 of transmission arrangement 2375 that isoperably supported on the tool mounting plate 2462 as shown in FIG. 50.In at least one embodiment, the rotary drive transmission 2490 includesa rotary drive assembly 2490′ that includes a gear 2491 that is coupledto a corresponding third one of the driven discs or elements 1304 on theadapter side of the tool mounting plate 2462 when the tool mountingportion 2460 is coupled to the tool holder 1270. See FIGS. 34 and 50.The rotary drive transmission 2490 further comprises a first rotarydriven gear 2492 that is rotatably supported on the tool mounting plate2462 in meshing engagement with a second rotary driven gear 2493 and therotary drive gear 2491. The second rotary driven gear 2493 is coupled toa proximal end portion 2443 of the drive shaft 2440.

Rotation of the rotary drive gear 2491 in a first rotary direction willresult in the rotation of the drive shaft 2440 in a first direction.Conversely, rotation of the rotary drive gear 2491 in a second rotarydirection (opposite to the first rotary direction) will cause the driveshaft 2440 to rotate in a second direction. As indicated above, thedrive shaft 2440 has a drive gear 2444 that is attached to its distalend 2442 and is in meshing engagement with a driven gear 2450 that isattached to the drive sleeve 2400. Thus, rotation of the drive shaft2440 results in rotation of the drive sleeve 2400.

A method of operating the surgical tool 2300 will now be described. Oncethe tool mounting portion 2462 has been operably coupled to the toolholder 1270 of the robotic system 1000 and oriented into positionadjacent the target tissue to be cut and stapled, if the anvil 2334 isnot already in the open position (FIG. 47), the robotic system 1000 mayapply the first rotary output motion to the shifter drive gear 2483which results in the axial movement of the closure clutch 2410 intomeshing engagement with the closure drive nut 2382 (if it is not alreadyin meshing engagement therewith). See FIG. 48. Once the controller 1001of the robotic system 1000 has confirmed that the closure clutch 2410 ismeshing engagement with the closure drive nut 2382 (e.g., by means ofsensor(s)) in the surgical end effector 2312 that are in communicationwith the robotic control system), the robotic controller 1001 may thenapply a second rotary output motion to the rotary drive gear 2492 which,as was described above, ultimately results in the rotation of the rotarydrive nut 2382 in the first direction which results in the axial travelof the closure tube 2370 in the distal direction “DD”. As the closuretube 2370 moved in the distal direction, it contacts a portion of theanvil 2323 and causes the anvil 2324 to pivot to the closed position toclamp the target tissue between the anvil 2324 and the surgical staplecartridge 2334. Once the robotic controller 1001 determines that theanvil 2334 has been pivoted to the closed position by correspondingsensor(s) in the surgical end effector 2312 in communication therewith,the robotic system 1000 discontinues the application of the secondrotary output motion to the rotary drive gear 2491. The roboticcontroller 1001 may also provide the surgeon with an indication that theanvil 2334 has been fully closed. The surgeon may then initiate thefiring procedure. In alternative embodiments, the firing procedure maybe automatically initiated by the robotic controller 1001. The roboticcontroller 1001 then applies the primary rotary control motion 2483 tothe shifter drive gear 2483 which results in the axial movement of theclosure clutch 2410 into meshing engagement with the face plate portion2424 of the knife drive shaft assembly 2420. See FIG. 49. Once thecontroller 1001 of the robotic system 1000 has confirmed that theclosure clutch 2410 is meshing engagement with the face plate portion2424 (by means of sensor(s)) in the end effector 2312 that are incommunication with the robotic controller 1001), the robotic controller1001 may then apply the second rotary output motion to the rotary drivegear 2492 which, as was described above, ultimately results in the axialmovement of the cutting instrument 2332 and sled portion 2333 in thedistal direction “DD” through the surgical staple cartridge 2334. As thecutting instrument 2332 moves distally through the surgical staplecartridge 2334, the tissue clamped therein is severed. As the sledportion 2333 is driven distally, it causes the staples within thesurgical staple cartridge to be driven through the severed tissue intoforming contact with the anvil 2324. Once the robotic controller 1001has determined that the cutting instrument 2324 has reached the endposition within the surgical staple cartridge 2334 (by means ofsensor(s)) in the end effector 2312 that are in communication with therobotic controller 1001), the robotic controller 1001 discontinues theapplication of the second rotary output motion to the rotary drive gear2491. Thereafter, the robotic controller 1001 applies the secondaryrotary output motion to the rotary drive gear 2491 which ultimatelyresults in the axial travel of the cutting instrument 2332 and sledportion 2333 in the proximal direction “PD” to the starting position.Once the robotic controller 1001 has determined that the cuttinginstrument 2324 has reached the staring position by means of sensor(s)in the surgical end effector 2312 that are in communication with therobotic controller 1001, the robotic controller 1001 discontinues theapplication of the secondary rotary output motion to the rotary drivegear 2491. Thereafter, the robotic controller 1001 applies the primaryrotary output motion to the shifter drive gear 2483 to cause the closureclutch 2410 to move into engagement with the rotary drive nut 2382. Oncethe closure clutch 2410 has been moved into meshing engagement with therotary drive nut 2382, the robotic controller 1001 then applies thesecondary output motion to the rotary drive gear 2491 which ultimatelyresults in the rotation of the rotary drive nut 2382 in the seconddirection to cause the closure tube 2370 to move in the proximaldirection “PD”. As can be seen in FIGS. 47-49, the closure tube 2370 hasan opening 2345 therein that engages the tab 2327 on the anvil 2324 tocause the anvil 2324 to pivot to the open position. In alternativeembodiments, a spring may also be employed to pivot the anvil 2324 tothe open position when the closure tube 2370 has been returned to thestarting position (FIG. 47).

FIGS. 51-55 illustrate yet another surgical tool 2500 that may beeffectively employed in connection with the robotic system 1000. Invarious forms, the surgical tool 2500 includes a surgical end effector2512 that includes a “first portion” in the form of an elongated channel2522 and a “second movable portion” in the form of a pivotallytranslatable clamping member, such as an anvil 2524, which aremaintained at a spacing that assures effective stapling and severing oftissue clamped in the surgical end effector 2512. As shown in theillustrated embodiment, the surgical end effector 2512 may include, inaddition to the previously-mentioned elongated channel 2522 and anvil2524, a “third movable portion” in the form of a cutting instrument2532, a sled (not shown), and a surgical staple cartridge 2534 that isremovably seated in the elongated channel 2522. The cutting instrument2532 may be, for example, a knife. The anvil 2524 may be pivotablyopened and closed at a pivot point 2525 connected to the proximate endof the elongated channel 2522. The anvil 2524 may also include a tab2527 at its proximate end that is configured to operably interface witha component of the mechanical closure system (described further below)to open and close the anvil 2524. When actuated, the knife 2532 and sledtravel longitudinally along the elongated channel 2522, thereby cuttingtissue clamped within the surgical end effector 2512. The movement ofthe sled along the elongated channel 2522 causes the staples of thesurgical staple cartridge 2534 to be driven through the severed tissueand against the closed anvil 2524, which turns the staples to fasten thesevered tissue. In one form, the elongated channel 2522 and the anvil2524 may be made of an electrically conductive material (such as metal)so that they may serve as part of the antenna that communicates withsensor(s) in the surgical end effector, as described above. The surgicalstaple cartridge 2534 could be made of a nonconductive material (such asplastic) and the sensor may be connected to or disposed in the surgicalstaple cartridge 2534, as described above.

It should be noted that although the embodiments of the surgical tool2500 described herein employ a surgical end effector 2512 that staplesthe severed tissue, in other embodiments different techniques forfastening or sealing the severed tissue may be used. For example, endeffectors that use RF energy or adhesives to fasten the severed tissuemay also be used. U.S. Pat. No. 5,709,680, entitled ELECTROSURGICALHEMOSTATIC DEVICE to Yates et al., and U.S. Pat. No. 5,688,270, entitledELECTROSURGICAL HEMOSTATIC DEVICE WITH RECESSED AND/OR OFFSET ELECTRODESto Yates et al., which are incorporated herein by reference, disclosecutting instruments that use RF energy to fasten the severed tissue.U.S. patent application Ser. No. 11/267,811 to Morgan et al., now U.S.Pat. No. 7,673,783, and U.S. patent application Ser. No. 11/267,383 toShelton et al., now U.S. Pat. No. 7,607,557, which are also incorporatedherein by reference, disclose cutting instruments that use adhesives tofasten the severed tissue. Accordingly, although the description hereinrefers to cutting/stapling operations and the like, it should berecognized that this is an exemplary embodiment and is not meant to belimiting. Other tissue-fastening techniques may also be used.

In the illustrated embodiment, the elongated channel 2522 of thesurgical end effector 2512 is coupled to an elongated shaft assembly2508 that is coupled to a tool mounting portion 2600. In at least oneembodiment, the elongated shaft assembly 2508 comprises a hollow spinetube 2540 that is non-movably coupled to a tool mounting plate 2602 ofthe tool mounting portion 2600. As can be seen in FIGS. 52 and 53, theproximal end 2523 of the elongated channel 2522 comprises a hollowtubular structure configured to be attached to the distal end 2541 ofthe spine tube 2540. In one embodiment, for example, the proximal end2523 of the elongated channel 2522 is welded or glued to the distal endof the spine tube 2540.

As can be further seen in FIGS. 52 and 53, in at least one non-limitingembodiment, the surgical tool 2500 further includes an axially movableactuation member in the form of a closure tube 2550 that is constrainedto move axially relative to the elongated channel 2522 and the spinetube 1540. The closure tube 2550 has a proximal end 2552 that has aninternal thread 2554 formed therein that is in threaded engagement witha rotatably movable portion in the form of a closure drive nut 2560.More specifically, the closure drive nut 2560 has a proximal end portion2562 that is rotatably supported relative to the elongated channel 2522and the spine tube 2540. For assembly purposes, the proximal end portion2562 is threadably attached to a retention ring 2570. The retention ring2570 is received in a groove 2529 formed between a shoulder 2527 on theproximal end 2523 of the elongated channel 2522 and the distal end 2541of the spine tube 1540. Such arrangement serves to rotatably support theclosure drive nut 2560 within the elongated channel 2522. Rotation ofthe closure drive nut 2560 will cause the closure tube 2550 to moveaxially as represented by arrow “D” in FIG. 52.

Extending through the spine tube 2540 and the closure drive nut 2560 isa drive member which, in at least one embodiment, comprises a knife bar2580 that has a distal end portion 2582 that is rotatably coupled to thecutting instrument 2532 such that the knife bar 2580 may rotate relativeto the cutting instrument 2582. As can be seen in FIG. 52-54, theclosure drive nut 2560 has a slot 2564 therein through which the knifebar 2580 can slidably extend. Such arrangement permits the knife bar2580 to move axially relative to the closure drive nut 2560. However,rotation of the knife bar 2580 about the longitudinal tool axis LT-LTwill also result in the rotation of the closure drive nut 2560. Theaxial direction in which the closure tube 2550 moves ultimately dependsupon the direction in which the knife bar 2580 and the closure drive nut2560 are rotated. As the closure tube 2550 is driven distally, thedistal end thereof will contact the anvil 2524 and cause the anvil 2524to pivot to a closed position. Upon application of an opening rotaryoutput motion from the robotic system 1000, the closure tube 2550 willbe driven in the proximal direction “PD” and pivot the anvil 2524 to theopen position by virtue of the engagement of the tab 2527 with theopening 2555 in the closure tube 2550.

In use, it may be desirable to rotate the surgical end effector 2512about the longitudinal tool axis LT-LT. In at least one embodiment, thetool mounting portion 2600 is configured to receive a correspondingfirst rotary output motion from the robotic system 1000 and convert thatfirst rotary output motion to a rotary control motion for rotating theelongated shaft assembly 2508 about the longitudinal tool axis LT-LT. Ascan be seen in FIG. 55, a proximal end 2542 of the hollow spine tube2540 is rotatably supported within a cradle arrangement 2603 attached toa tool mounting plate 2602 of the tool mounting portion 2600. Variousembodiments of the surgical tool 2500 further include a transmissionarrangement, generally depicted as 2605, that is operably supported onthe tool mounting plate 2602. In various forms the transmissionarrangement 2605 include a rotation gear 2544 that is formed on orattached to the proximal end 2542 of the spine tube 2540 for meshingengagement with a rotation drive assembly 2610 that is operablysupported on the tool mounting plate 2602. In at least one embodiment, arotation drive gear 2612 is coupled to a corresponding first one of therotational bodies, driven discs or elements 1304 on the adapter side ofthe tool mounting plate 2602 when the tool mounting portion 2600 iscoupled to the tool holder 1270. See FIGS. 34 and 55. The rotation driveassembly 2610 further comprises a rotary driven gear 2614 that isrotatably supported on the tool mounting plate 2602 in meshingengagement with the rotation gear 2544 and the rotation drive gear 2612.Application of a first rotary output motion from the robotic system 1000through the tool drive assembly 1010 to the corresponding drivenrotational body 1304 will thereby cause rotation of the rotation drivegear 2612 by virtue of being operably coupled thereto. Rotation of therotation drive gear 2612 ultimately results in the rotation of theelongated shaft assembly 2508 (and the end effector 2512) about thelongitudinal tool axis LT-LT.

Closure of the anvil 2524 relative to the surgical staple cartridge 2534is accomplished by axially moving the closure tube 2550 in the distaldirection “DD”. Axial movement of the closure tube 2550 in the distaldirection “DD” is accomplished by applying a rotary control motion tothe closure drive nut 2382. In various embodiments, the closure drivenut 2560 is rotated by applying a rotary output motion to the knife bar2580. Rotation of the knife bar 2580 is controlled by applying rotaryoutput motions to a rotary closure system 2620 that is operablysupported on the tool mounting plate 2602 as shown in FIG. 55. In atleast one embodiment, the rotary closure system 2620 includes a closuredrive gear 2622 that is coupled to a corresponding second one of thedriven rotatable body portions discs or elements 1304 on the adapterside of the tool mounting plate 2462 when the tool mounting portion 2600is coupled to the tool holder 1270. See FIGS. 34 and 55. The closuredrive gear 2622, in at least one embodiment, is in meshing drivingengagement with a closure gear train, generally depicted as 2623. Theclosure gear drive rain 2623 comprises a first driven closure gear 2624that is rotatably supported on the tool mounting plate 2602. The firstclosure driven gear 2624 is attached to a second closure driven gear2626 by a drive shaft 2628. The second closure driven gear 2626 is inmeshing engagement with a third closure driven gear 2630 that isrotatably supported on the tool mounting plate 2602. Rotation of theclosure drive gear 2622 in a second rotary direction will result in therotation of the third closure driven gear 2630 in a second direction.Conversely, rotation of the closure drive gear 2483 in a secondaryrotary direction (opposite to the second rotary direction) will causethe third closure driven gear 2630 to rotate in a secondary direction.

As can be seen in FIG. 55, a drive shaft assembly 2640 is coupled to aproximal end of the knife bar 2580. In various embodiments, the driveshaft assembly 2640 includes a proximal portion 2642 that has a squarecross-sectional shape. The proximal portion 2642 is configured toslidably engage a correspondingly shaped aperture in the third drivengear 2630. Such arrangement results in the rotation of the drive shaftassembly 2640 (and knife bar 2580) when the third driven gear 2630 isrotated. The drive shaft assembly 2640 is axially advanced in the distaland proximal directions by a knife drive assembly 2650. One form of theknife drive assembly 2650 comprises a rotary drive gear 2652 that iscoupled to a corresponding third one of the driven rotatable bodyportions, discs or elements 1304 on the adapter side of the toolmounting plate 2462 when the tool mounting portion 2600 is coupled tothe tool holder 1270. See FIGS. 34 and 55. The rotary driven gear 2652is in meshing driving engagement with a gear train, generally depictedas 2653. In at least one form, the gear train 2653 further comprises afirst rotary driven gear assembly 2654 that is rotatably supported onthe tool mounting plate 2602. The first rotary driven gear assembly 2654is in meshing engagement with a third rotary driven gear assembly 2656that is rotatably supported on the tool mounting plate 2602 and which isin meshing engagement with a fourth rotary driven gear assembly 2658that is in meshing engagement with a threaded portion 2644 of the driveshaft assembly 2640. Rotation of the rotary drive gear 2652 in a thirdrotary direction will result in the axial advancement of the drive shaftassembly 2640 and knife bar 2580 in the distal direction “DD”.Conversely, rotation of the rotary drive gear 2652 in a tertiary rotarydirection (opposite to the third rotary direction) will cause the driveshaft assembly 2640 and the knife bar 2580 to move in the proximaldirection.

A method of operating the surgical tool 2500 will now be described. Oncethe tool mounting portion 2600 has been operably coupled to the toolholder 1270 of the robotic system 1000, the robotic system 1000 canorient the surgical end effector 2512 in position adjacent the targettissue to be cut and stapled. If the anvil 2524 is not already in theopen position (FIG. 52), the robotic system 1000 may apply the secondrotary output motion to the closure drive gear 2622 which results in therotation of the knife bar 2580 in a second direction. Rotation of theknife bar 2580 in the second direction results in the rotation of theclosure drive nut 2560 in a second direction. As the closure drive nut2560 rotates in the second direction, the closure tube 2550 moves in theproximal direction “PD”. As the closure tube 2550 moves in the proximaldirection “PD”, the tab 2527 on the anvil 2524 interfaces with theopening 2555 in the closure tube 2550 and causes the anvil 2524 to pivotto the open position. In addition or in alternative embodiments, aspring (not shown) may be employed to pivot the anvil 2354 to the openposition when the closure tube 2550 has been returned to the startingposition (FIG. 52). The opened surgical end effector 2512 may then bemanipulated by the robotic system 1000 to position the target tissuebetween the open anvil 2524 and the surgical staple cartridge 2534.Thereafter, the surgeon may initiate the closure process by activatingthe robotic control system 1000 to apply the second rotary output motionto the closure drive gear 2622 which, as was described above, ultimatelyresults in the rotation of the closure drive nut 2382 in the seconddirection which results in the axial travel of the closure tube 2250 inthe distal direction “DD”. As the closure tube 2550 moves in the distaldirection, it contacts a portion of the anvil 2524 and causes the anvil2524 to pivot to the closed position to clamp the target tissue betweenthe anvil 2524 and the staple cartridge 2534. Once the roboticcontroller 1001 determines that the anvil 2524 has been pivoted to theclosed position by corresponding sensor(s) in the end effector 2512 thatare in communication therewith, the robotic controller 1001 discontinuesthe application of the second rotary output motion to the closure drivegear 2622. The robotic controller 1001 may also provide the surgeon withan indication that the anvil 2524 has been fully closed. The surgeon maythen initiate the firing procedure. In alternative embodiments, thefiring procedure may be automatically initiated by the roboticcontroller 1001.

After the robotic controller 1001 has determined that the anvil 2524 isin the closed position, the robotic controller 1001 then applies thethird rotary output motion to the rotary drive gear 2652 which resultsin the axial movement of the drive shaft assembly 2640 and knife bar2580 in the distal direction “DD”. As the cutting instrument 2532 movesdistally through the surgical staple cartridge 2534, the tissue clampedtherein is severed. As the sled portion (not shown) is driven distally,it causes the staples within the surgical staple cartridge 2534 to bedriven through the severed tissue into forming contact with the anvil2524. Once the robotic controller 1001 has determined that the cuttinginstrument 2532 has reached the end position within the surgical staplecartridge 2534 by means of sensor(s) in the surgical end effector 2512that are in communication with the robotic controller 1001, the roboticcontroller 1001 discontinues the application of the second rotary outputmotion to the rotary drive gear 2652. Thereafter, the robotic controller1001 applies the secondary rotary control motion to the rotary drivegear 2652 which ultimately results in the axial travel of the cuttinginstrument 2532 and sled portion in the proximal direction “PD” to thestarting position. Once the robotic controller 1001 has determined thatthe cutting instrument 2524 has reached the staring position by means ofsensor(s) in the end effector 2512 that are in communication with therobotic controller 1001, the robotic controller 1001 discontinues theapplication of the secondary rotary output motion to the rotary drivegear 2652. Thereafter, the robotic controller 1001 may apply thesecondary rotary output motion to the closure drive gear 2622 whichresults in the rotation of the knife bar 2580 in a secondary direction.Rotation of the knife bar 2580 in the secondary direction results in therotation of the closure drive nut 2560 in a secondary direction. As theclosure drive nut 2560 rotates in the secondary direction, the closuretube 2550 moves in the proximal direction “PD” to the open position.

FIGS. 56-61B illustrate yet another surgical tool 2700 that may beeffectively employed in connection with the robotic system 1000. Invarious forms, the surgical tool 2700 includes a surgical end effector2712 that includes a “first portion” in the form of an elongated channel2722 and a “second movable portion” in one form comprising a pivotallytranslatable clamping member, such as an anvil 2724, which aremaintained at a spacing that assures effective stapling and severing oftissue clamped in the surgical end effector 2712. As shown in theillustrated embodiment, the surgical end effector 2712 may include, inaddition to the previously-mentioned channel 2722 and anvil 2724, a“third movable portion” in the form of a cutting instrument 2732, a sled(not shown), and a surgical staple cartridge 2734 that is removablyseated in the elongated channel 2722. The cutting instrument 2732 maybe, for example, a knife. The anvil 2724 may be pivotably opened andclosed at a pivot point 2725 connected to the proximal end of theelongated channel 2722. The anvil 2724 may also include a tab 2727 atits proximal end that interfaces with a component of the mechanicalclosure system (described further below) to open and close the anvil2724. When actuated, the knife 2732 and sled to travel longitudinallyalong the elongated channel 2722, thereby cutting tissue clamped withinthe surgical end effector 2712. The movement of the sled along theelongated channel 2722 causes the staples of the surgical staplecartridge 2734 to be driven through the severed tissue and against theclosed anvil 2724, which turns the staples to fasten the severed tissue.In one form, the elongated channel 2722 and the anvil 2724 may be madeof an electrically conductive material (such as metal) so that they mayserve as part of the antenna that communicates with sensor(s) in thesurgical end effector, as described above. The surgical staple cartridge2734 could be made of a nonconductive material (such as plastic) and thesensor may be connected to or disposed in the surgical staple cartridge2734, as described above.

It should be noted that although the embodiments of the surgical tool2500 described herein employ a surgical end effector 2712 that staplesthe severed tissue, in other embodiments different techniques forfastening or sealing the severed tissue may be used. For example, endeffectors that use RF energy or adhesives to fasten the severed tissuemay also be used. U.S. Pat. No. 5,709,680, entitled ELECTROSURGICALHEMOSTATIC DEVICE to Yates et al., and U.S. Pat. No. 5,688,270, entitledELECTROSURGICAL HEMOSTATIC DEVICE WITH RECESSED AND/OR OFFSET ELECTRODESto Yates et al., which are incorporated herein by reference, disclosecutting instruments that use RF energy to fasten the severed tissue.U.S. patent application Ser. No. 11/267,811 to Morgan et al., now U.S.Pat. No. 7,673,783, and U.S. patent application Ser. No. 11/267,383 toShelton et al., now U.S. Pat. No. 7,607,557, which are also incorporatedherein by reference, disclose cutting instruments that use adhesives tofasten the severed tissue. Accordingly, although the description hereinrefers to cutting/stapling operations and the like, it should berecognized that this is an exemplary embodiment and is not meant to belimiting. Other tissue-fastening techniques may also be used.

In the illustrated embodiment, the elongated channel 2722 of thesurgical end effector 2712 is coupled to an elongated shaft assembly2708 that is coupled to a tool mounting portion 2900. Although notshown, the elongated shaft assembly 2708 may include an articulationjoint to permit the surgical end effector 2712 to be selectivelyarticulated about an axis that is substantially transverse to the toolaxis LT-LT. In at least one embodiment, the elongated shaft assembly2708 comprises a hollow spine tube 2740 that is non-movably coupled to atool mounting plate 2902 of the tool mounting portion 2900. As can beseen in FIGS. 57 and 58, the proximal end 2723 of the elongated channel2722 comprises a hollow tubular structure that is attached to the spinetube 2740 by means of a mounting collar 2790. A cross-sectional view ofthe mounting collar 2790 is shown in FIG. 59. In various embodiments,the mounting collar 2790 has a proximal flanged end 2791 that isconfigured for attachment to the distal end of the spine tube 2740. Inat least one embodiment, for example, the proximal flanged end 2791 ofthe mounting collar 2790 is welded or glued to the distal end of thespine tube 2740. As can be further seen in FIGS. 57 and 58, the mountingcollar 2790 further has a mounting hub portion 2792 that is sized toreceive the proximal end 2723 of the elongated channel 2722 thereon. Theproximal end 2723 of the elongated channel 2722 is non-movably attachedto the mounting hub portion 2792 by, for example, welding, adhesive,etc.

As can be further seen in FIGS. 57 and 58, the surgical tool 2700further includes an axially movable actuation member in the form of aclosure tube 2750 that is constrained to move axially relative to theelongated channel 2722. The closure tube 2750 has a proximal end 2752that has an internal thread 2754 formed therein that is in threadedengagement with a rotatably movable portion in the form of a closuredrive nut 2760. More specifically, the closure drive nut 2760 has aproximal end portion 2762 that is rotatably supported relative to theelongated channel 2722 and the spine tube 2740. For assembly purposes,the proximal end portion 2762 is threadably attached to a retention ring2770. The retention ring 2770 is received in a groove 2729 formedbetween a shoulder 2727 on the proximal end 2723 of the channel 2722 andthe mounting hub 2729 of the mounting collar 2790. Such arrangementserves to rotatably support the closure drive nut 2760 within thechannel 2722. Rotation of the closure drive nut 2760 will cause theclosure tube 2750 to move axially as represented by arrow “D” in FIG.57.

Extending through the spine tube 2740, the mounting collar 2790, and theclosure drive nut 2760 is a drive member, which in at least oneembodiment, comprises a knife bar 2780 that has a distal end portion2782 that is coupled to the cutting instrument 2732. As can be seen inFIGS. 57 and 58, the mounting collar 2790 has a passage 2793therethrough for permitting the knife bar 2780 to slidably passtherethrough. Similarly, the closure drive nut 2760 has a slot 2764therein through which the knife bar 2780 can slidably extend. Sucharrangement permits the knife bar 2780 to move axially relative to theclosure drive nut 2760.

Actuation of the anvil 2724 is controlled by a rotary driven closureshaft 2800. As can be seen in FIGS. 57 and 58, a distal end portion 2802of the closure drive shaft 2800 extends through a passage 2794 in themounting collar 2790 and a closure gear 2804 is attached thereto. Theclosure gear 2804 is configured for driving engagement with the innersurface 2761 of the closure drive nut 2760. Thus, rotation of theclosure shaft 2800 will also result in the rotation of the closure drivenut 2760. The axial direction in which the closure tube 2750 movesultimately depends upon the direction in which the closure shaft 2800and the closure drive nut 2760 are rotated. For example, in response toone rotary closure motion received from the robotic system 1000, theclosure tube 2750 will be driven in the distal direction “DD”. As theclosure tube 2750 is driven distally, the opening 2745 will engage thetab 2727 on the anvil 2724 and cause the anvil 2724 to pivot to a closedposition. Upon application of an opening rotary motion from the roboticsystem 1000, the closure tube 2750 will be driven in the proximaldirection “PD” and pivot the anvil 2724 to the open position. In variousembodiments, a spring (not shown) may be employed to bias the anvil 2724to the open position (FIG. 57).

In use, it may be desirable to rotate the surgical end effector 2712about the longitudinal tool axis LT-LT. In at least one embodiment, thetool mounting portion 2900 is configured to receive a correspondingfirst rotary output motion from the robotic system 1000 for rotating theelongated shaft assembly 2708 about the tool axis LT-LT. As can be seenin FIG. 61, a proximal end 2742 of the hollow spine tube 2740 isrotatably supported within a cradle arrangement 2903 and a bearingassembly 2904 that are attached to a tool mounting plate 2902 of thetool mounting portion 2900. A rotation gear 2744 is formed on orattached to the proximal end 2742 of the spine tube 2740 for meshingengagement with a rotation drive assembly 2910 that is operablysupported on the tool mounting plate 2902. In at least one embodiment, arotation drive gear 2912 is coupled to a corresponding first one of thedriven discs or elements 1304 on the adapter side of the tool mountingplate 2602 when the tool mounting portion 2600 is coupled to the toolholder 1270. See FIGS. 34 and 61. The rotation drive assembly 2910further comprises a rotary driven gear 2914 that is rotatably supportedon the tool mounting plate 2902 in meshing engagement with the rotationgear 2744 and the rotation drive gear 2912. Application of a firstrotary control motion from the robotic system 1000 through the toolholder 1270 and the adapter 1240 to the corresponding driven element1304 will thereby cause rotation of the rotation drive gear 2912 byvirtue of being operably coupled thereto. Rotation of the rotation drivegear 2912 ultimately results in the rotation of the elongated shaftassembly 2708 (and the end effector 2712) about the longitudinal toolaxis LT-LT (primary rotary motion).

Closure of the anvil 2724 relative to the staple cartridge 2734 isaccomplished by axially moving the closure tube 2750 in the distaldirection “DD”. Axial movement of the closure tube 2750 in the distaldirection “DD” is accomplished by applying a rotary control motion tothe closure drive nut 2760. In various embodiments, the closure drivenut 2760 is rotated by applying a rotary output motion to the closuredrive shaft 2800. As can be seen in FIG. 61, a proximal end portion 2806of the closure drive shaft 2800 has a driven gear 2808 thereon that isin meshing engagement with a closure drive assembly 2920. In variousembodiments, the closure drive system 2920 includes a closure drive gear2922 that is coupled to a corresponding second one of the drivenrotational bodies or elements 1304 on the adapter side of the toolmounting plate 2462 when the tool mounting portion 2900 is coupled tothe tool holder 1270. See FIGS. 34 and 61. The closure drive gear 2922is supported in meshing engagement with a closure gear train, generallydepicted as 2923. In at least one form, the closure gear rain 2923comprises a first driven closure gear 2924 that is rotatably supportedon the tool mounting plate 2902. The first closure driven gear 2924 isattached to a second closure driven gear 2926 by a drive shaft 2928. Thesecond closure driven gear 2926 is in meshing engagement with aplanetary gear assembly 2930. In various embodiments, the planetary gearassembly 2930 includes a driven planetary closure gear 2932 that isrotatably supported within the bearing assembly 2904 that is mounted ontool mounting plate 2902. As can be seen in FIGS. 61 and 61B, theproximal end portion 2806 of the closure drive shaft 2800 is rotatablysupported within the proximal end portion 2742 of the spine tube 2740such that the driven gear 2808 is in meshing engagement with centralgear teeth 2934 formed on the planetary gear 2932. As can also be seenin FIG. 61A, two additional support gears 2936 are attached to orrotatably supported relative to the proximal end portion 2742 of thespine tube 2740 to provide bearing support thereto. Such arrangementwith the planetary gear assembly 2930 serves to accommodate rotation ofthe spine shaft 2740 by the rotation drive assembly 2910 whilepermitting the closure driven gear 2808 to remain in meshing engagementwith the closure drive system 2920. In addition, rotation of the closuredrive gear 2922 in a first direction will ultimately result in therotation of the closure drive shaft 2800 and closure drive nut 2760which will ultimately result in the closure of the anvil 2724 asdescribed above. Conversely, rotation of the closure drive gear 2922 ina second opposite direction will ultimately result in the rotation ofthe closure drive nut 2760 in an opposite direction which results in theopening of the anvil 2724.

As can be seen in FIG. 61, the proximal end 2784 of the knife bar 2780has a threaded shaft portion 2786 attached thereto which is in drivingengagement with a knife drive assembly 2940. In various embodiments, thethreaded shaft portion 2786 is rotatably supported by a bearing 2906attached to the tool mounting plate 2902. Such arrangement permits thethreaded shaft portion 2786 to rotate and move axially relative to thetool mounting plate 2902. The knife bar 2780 is axially advanced in thedistal and proximal directions by the knife drive assembly 2940. Oneform of the knife drive assembly 2940 comprises a rotary drive gear 2942that is coupled to a corresponding third one of the rotatable bodies,driven discs or elements 1304 on the adapter side of the tool mountingplate 2902 when the tool mounting portion 2900 is coupled to the toolholder 1270. See FIGS. 34 and 61. The rotary drive gear 2942 is inmeshing engagement with a knife gear train, generally depicted as 2943.In various embodiments, the knife gear train 2943 comprises a firstrotary driven gear assembly 2944 that is rotatably supported on the toolmounting plate 2902. The first rotary driven gear assembly 2944 is inmeshing engagement with a third rotary driven gear assembly 2946 that isrotatably supported on the tool mounting plate 2902 and which is inmeshing engagement with a fourth rotary driven gear assembly 2948 thatis in meshing engagement with the threaded portion 2786 of the knife bar2780. Rotation of the rotary drive gear 2942 in one direction willresult in the axial advancement of the knife bar 2780 in the distaldirection “DD”. Conversely, rotation of the rotary drive gear 2942 in anopposite direction will cause the knife bar 2780 to move in the proximaldirection. Tool 2700 may otherwise be used as described above.

FIGS. 62 and 63 illustrate a surgical tool embodiment 2700 that issubstantially identical to tool 2700 that was described in detail above.However tool 2700′ includes a pressure sensor 2950 that is configured toprovide feedback to the robotic controller 1001 concerning the amount ofclamping pressure experienced by the anvil 2724. In various embodiments,for example, the pressure sensor may comprise a spring biased contactswitch. For a continuous signal, it would use either a cantilever beamwith a strain gage on it or a dome button top with a strain gage on theinside. Another version may comprise an off switch that contacts only ata known desired load. Such arrangement would include a dome on the basedwherein the dome is one electrical pole and the base is the otherelectrical pole. Such arrangement permits the robotic controller 1001 toadjust the amount of clamping pressure being applied to the tissuewithin the surgical end effector 2712 by adjusting the amount of closingpressure applied to the anvil 2724. Those of ordinary skill in the artwill understand that such pressure sensor arrangement may be effectivelyemployed with several of the surgical tool embodiments described hereinas well as their equivalent structures.

FIG. 64 illustrates a portion of another surgical tool 3000 that may beeffectively used in connection with a robotic system 1000. The surgicaltool 3003 employs on-board motor(s) for powering various components of asurgical end effector cutting instrument. In at least one non-limitingembodiment for example, the surgical tool 3000 includes a surgical endeffector in the form of an endocutter (not shown) that has an anvil (notshown) and surgical staple cartridge arrangement (not shown) of thetypes and constructions described above. The surgical tool 3000 alsoincludes an elongated shaft (not shown) and anvil closure arrangement(not shown) of the types described above. Thus, this portion of theDetailed Description will not repeat the description of those componentsbeyond that which is necessary to appreciate the unique and novelattributes of the various embodiments of surgical tool 3000.

In the depicted embodiment, the end effector includes a cuttinginstrument 3002 that is coupled to a knife bar 3003. As can be seen inFIG. 64, the surgical tool 3000 includes a tool mounting portion 3010that includes a tool mounting plate 3012 that is configured tomountingly interface with the adaptor portion 1240′ which is coupled tothe robotic system 1000 in the various manners described above. The toolmounting portion 3010 is configured to operably support a transmissionarrangement 3013 thereon. In at least one embodiment, the adaptorportion 1240′ may be identical to the adaptor portion 1240 described indetail above without the powered rotation bodies and disc membersemployed by adapter 1240. In other embodiments, the adaptor portion1240′ may be identical to adaptor portion 1240. Still othermodifications which are considered to be within the spirit and scope ofthe various forms of the present invention may employ one or more of themechanical motions (i.e., rotary motion(s)) from the tool holder portion1270 (as described hereinabove) to power/actuate the transmissionarrangement 3013 while also employing one or more motors within the toolmounting portion 3010 to power one or more other components of thesurgical end effector. In addition, while the end effector of thedepicted embodiment comprises an endocutter, those of ordinary skill inthe art will understand that the unique and novel attributes of thedepicted embodiment may be effectively employed in connection with othertypes of surgical end effectors without departing from the spirit andscope of various forms of the present invention.

In various embodiments, the tool mounting plate 3012 is configured to atleast house a first firing motor 3011 for supplying firing andretraction motions to the knife bar 3003 which is coupled to orotherwise operably interfaces with the cutting instrument 3002. The toolmounting plate 3012 has an array of electrical connecting pins 3014which are configured to interface with the slots 1258 (FIG. 33) in theadapter 1240′. Such arrangement permits the controller 1001 of therobotic system 1000 to provide control signals to the electronic controlcircuit 3020 of the surgical tool 3000. While the interface is describedherein with reference to mechanical, electrical, and magnetic couplingelements, it should be understood that a wide variety of telemetrymodalities might be used, including infrared, inductive coupling, or thelike.

Control circuit 3020 is shown in schematic form in FIG. 64. In one formor embodiment, the control circuit 3020 includes a power supply in theform of a battery 3022 that is coupled to an on-off solenoid poweredswitch 3024. Control circuit 3020 further includes an on/off firingsolenoid 3026 that is coupled to a double pole switch 3028 forcontrolling the rotational direction of the motor 3011. Thus, when thecontroller 1001 of the robotic system 1000 supplies an appropriatecontrol signal, switch 3024 will permit battery 3022 to supply power tothe double pole switch 3028. The controller 1001 of the robotic system1000 will also supply an appropriate signal to the double pole switch3028 to supply power to the motor 3011. When it is desired to fire thesurgical end effector (i.e., drive the cutting instrument 3002 distallythrough tissue clamped in the surgical end effector, the double poleswitch 3028 will be in a first position. When it is desired to retractthe cutting instrument 3002 to the starting position, the double poleswitch 3028 will be moved to the second position by the controller 1001.

Various embodiments of the surgical tool 3000 also employ a gear box3030 that is sized, in cooperation with a firing gear train 3031 that,in at least one non-limiting embodiment, comprises a firing drive gear3032 that is in meshing engagement with a firing driven gear 3034 forgenerating a desired amount of driving force necessary to drive thecutting instrument 3002 through tissue and to drive and form staples inthe various manners described herein. In the embodiment depicted in FIG.61, the driven gear 3034 is coupled to a screw shaft 3036 that is inthreaded engagement with a screw nut arrangement 3038 that isconstrained to move axially (represented by arrow “D”). The screw nutarrangement 3038 is attached to the firing bar 3003. Thus, by rotatingthe screw shaft 3036 in a first direction, the cutting instrument 3002is driven in the distal direction “DD” and rotating the screw shaft inan opposite second direction, the cutting instrument 3002 may beretracted in the proximal direction “PD”.

FIG. 65 illustrates a portion of another surgical tool 3000′ that issubstantially identical to tool 3000 described above, except that thedriven gear 3034 is attached to a drive shaft 3040. The drive shaft 3040is attached to a second driver gear 3042 that is in meshing engagementwith a third driven gear 3044 that is in meshing engagement with a screw3046 coupled to the firing bar 3003.

FIG. 66 illustrates another surgical tool 3200 that may be effectivelyused in connection with a robotic system 1000. In this embodiment, thesurgical tool 3200 includes a surgical end effector 3212 that in onenon-limiting form, comprises a component portion that is selectivelymovable between first and second positions relative to at least oneother end effector component portion. As will be discussed in furtherdetail below, the surgical tool 3200 employs on-board motors forpowering various components of a transmission arrangement 3305. Thesurgical end effector 3212 includes an elongated channel 3222 thatoperably supports a surgical staple cartridge 3234. The elongatedchannel 3222 has a proximal end 3223 that slidably extends into a hollowelongated shaft assembly 3208 that is coupled to a tool mounting portion3300. In addition, the surgical end effector 3212 includes an anvil 3224that is pivotally coupled to the elongated channel 3222 by a pair oftrunnions 3225 that are received within corresponding openings 3229 inthe elongated channel 3222. A distal end portion 3209 of the shaftassembly 3208 includes an opening 3245 into which a tab 3227 on theanvil 3224 is inserted in order to open the anvil 3224 as the elongatedchannel 3222 is moved axially in the proximal direction “PD” relative tothe distal end portion 3209 of the shaft assembly 3208. In variousembodiments, a spring (not shown) may be employed to bias the anvil 3224to the open position.

As indicated above, the surgical tool 3200 includes a tool mountingportion 3300 that includes a tool mounting plate 3302 that is configuredto operably support the transmission arrangement 3305 and to mountinglyinterface with the adaptor portion 1240′ which is coupled to the roboticsystem 1000 in the various manners described above. In at least oneembodiment, the adaptor portion 1240′ may be identical to the adaptorportion 1240 described in detail above without the powered disc membersemployed by adapter 1240. In other embodiments, the adaptor portion1240′ may be identical to adaptor portion 1240. However, in suchembodiments, because the various components of the surgical end effector3212 are all powered by motor(s) in the tool mounting portion 3300, thesurgical tool 3200 will not employ or require any of the mechanical(i.e., non-electrical) actuation motions from the tool holder portion1270 to power the surgical end effector 3200 components. Still othermodifications which are considered to be within the spirit and scope ofthe various forms of the present invention may employ one or more of themechanical motions from the tool holder portion 1270 (as describedhereinabove) to power/actuate one or more of the surgical end effectorcomponents while also employing one or more motors within the toolmounting portion to power one or more other components of the surgicalend effector.

In various embodiments, the tool mounting plate 3302 is configured tosupport a first firing motor 3310 for supplying firing and retractionmotions to the transmission arrangement 3305 to drive a knife bar 3335that is coupled to a cutting instrument 3332 of the type describedabove. As can be seen in FIG. 66, the tool mounting plate 3212 has anarray of electrical connecting pins 3014 which are configured tointerface with the slots 1258 (FIG. 33) in the adapter 1240′. Sucharrangement permits the controller 1001 of the robotic system 1000 toprovide control signals to the electronic control circuits 3320, 3340 ofthe surgical tool 3200. While the interface is described herein withreference to mechanical, electrical, and magnetic coupling elements, itshould be understood that a wide variety of telemetry modalities mightbe used, including infrared, inductive coupling, or the like.

In one form or embodiment, the first control circuit 3320 includes afirst power supply in the form of a first battery 3322 that is coupledto a first on-off solenoid powered switch 3324. The first firing controlcircuit 3320 further includes a first on/off firing solenoid 3326 thatis coupled to a first double pole switch 3328 for controlling therotational direction of the first firing motor 3310. Thus, when therobotic controller 1001 supplies an appropriate control signal, thefirst switch 3324 will permit the first battery 3322 to supply power tothe first double pole switch 3328. The robotic controller 1001 will alsosupply an appropriate signal to the first double pole switch 3328 tosupply power to the first firing motor 3310. When it is desired to firethe surgical end effector (i.e., drive the cutting instrument 3232distally through tissue clamped in the surgical end effector 3212, thefirst switch 3328 will be positioned in a first position by the roboticcontroller 1001. When it is desired to retract the cutting instrument3232 to the starting position, the robotic controller 1001 will send theappropriate control signal to move the first switch 3328 to the secondposition.

Various embodiments of the surgical tool 3200 also employ a first gearbox 3330 that is sized, in cooperation with a firing drive gear 3332coupled thereto that operably interfaces with a firing gear train 3333.In at least one non-limiting embodiment, the firing gear train 333comprises a firing driven gear 3334 that is in meshing engagement withdrive gear 3332, for generating a desired amount of driving forcenecessary to drive the cutting instrument 3232 through tissue and todrive and form staples in the various manners described herein. In theembodiment depicted in FIG. 66, the driven gear 3334 is coupled to adrive shaft 3335 that has a second driven gear 3336 coupled thereto. Thesecond driven gear 3336 is supported in meshing engagement with a thirddriven gear 3337 that is in meshing engagement with a fourth driven gear3338. The fourth driven gear 3338 is in meshing engagement with athreaded proximal portion 3339 of the knife bar 3235 that is constrainedto move axially. Thus, by rotating the drive shaft 3335 in a firstdirection, the cutting instrument 3232 is driven in the distal direction“DD” and rotating the drive shaft 3335 in an opposite second direction,the cutting instrument 3232 may be retracted in the proximal direction“PD”.

As indicated above, the opening and closing of the anvil 3224 iscontrolled by axially moving the elongated channel 3222 relative to theelongated shaft assembly 3208. The axial movement of the elongatedchannel 3222 is controlled by a closure control system 3339. In variousembodiments, the closure control system 3339 includes a closure shaft3340 which has a hollow threaded end portion 3341 that threadablyengages a threaded closure rod 3342. The threaded end portion 3341 isrotatably supported in a spine shaft 3343 that operably interfaces withthe tool mounting portion 3300 and extends through a portion of theshaft assembly 3208 as shown. The closure system 3339 further comprisesa closure control circuit 3350 that includes a second power supply inthe form of a second battery 3352 that is coupled to a second on-offsolenoid powered switch 3354. Closure control circuit 3350 furtherincludes a second on/off firing solenoid 3356 that is coupled to asecond double pole switch 3358 for controlling the rotation of a secondclosure motor 3360. Thus, when the robotic controller 1001 supplies anappropriate control signal, the second switch 3354 will permit thesecond battery 3352 to supply power to the second double pole switch3354. The robotic controller 1001 will also supply an appropriate signalto the second double pole switch 3358 to supply power to the secondmotor 3360. When it is desired to close the anvil 3224, the secondswitch 3348 will be in a first position. When it is desired to open theanvil 3224, the second switch 3348 will be moved to a second position.

Various embodiments of tool mounting portion 3300 also employ a secondgear box 3362 that is coupled to a closure drive gear 3364. The closuredrive gear 3364 is in meshing engagement with a closure gear train 3363.In various non-limiting forms, the closure gear train 3363 includes aclosure driven gear 3365 that is attached to a closure drive shaft 3366.Also attached to the closure drive shaft 3366 is a closure drive gear3367 that is in meshing engagement with a closure shaft gear 3360attached to the closure shaft 3340. FIG. 66 depicts the end effector3212 in the open position. As indicated above, when the threaded closurerod 3342 is in the position depicted in FIG. 66, a spring (not shown)biases the anvil 3224 to the open position. When it is desired to closethe anvil 3224, the robotic controller 1001 will activate the secondmotor 3360 to rotate the closure shaft 3340 to draw the threaded closurerod 3342 and the channel 3222 in the proximal direction ‘PD’. As theanvil 3224 contacts the distal end portion 3209 of the shaft 3208, theanvil 3224 is pivoted to the closed position.

A method of operating the surgical tool 3200 will now be described. Oncethe tool mounting portion 3302 has be operably coupled to the toolholder 1270 of the robotic system 1000, the robotic system 1000 canorient the end effector 3212 in position adjacent the target tissue tobe cut and stapled. If the anvil 3224 is not already in the openposition, the robotic controller 1001 may activate the second closuremotor 3360 to drive the channel 3222 in the distal direction to theposition depicted in FIG. 66. Once the robotic controller 1001determines that the surgical end effector 3212 is in the open positionby sensor(s) in the and effector and/or the tool mounting portion 3300,the robotic controller 1001 may provide the surgeon with a signal toinform the surgeon that the anvil 3224 may then be closed. Once thetarget tissue is positioned between the open anvil 3224 and the surgicalstaple cartridge 3234, the surgeon may then commence the closure processby activating the robotic controller 1001 to apply a closure controlsignal to the second closure motor 3360. The second closure motor 3360applies a rotary motion to the closure shaft 3340 to draw the channel3222 in the proximal direction “PD” until the anvil 3224 has beenpivoted to the closed position. Once the robotic controller 1001determines that the anvil 3224 has been moved to the closed position bysensor(s) in the surgical end effector 3212 and/or in the tool mountingportion 3300 that are in communication with the robotic control system,the motor 3360 may be deactivated. Thereafter, the firing process may becommenced either manually by the surgeon activating a trigger, button,etc. on the controller 1001 or the controller 1001 may automaticallycommence the firing process.

To commence the firing process, the robotic controller 1001 activatesthe firing motor 3310 to drive the firing bar 3235 and the cuttinginstrument 3232 in the distal direction “DD”. Once robotic controller1001 has determined that the cutting instrument 3232 has moved to theending position within the surgical staple cartridge 3234 by means ofsensors in the surgical end effector 3212 and/or the motor drive portion3300, the robotic controller 1001 may provide the surgeon with anindication signal. Thereafter the surgeon may manually activate thefirst motor 3310 to retract the cutting instrument 3232 to the startingposition or the robotic controller 1001 may automatically activate thefirst motor 3310 to retract the cutting element 3232.

The embodiment depicted in FIG. 66 does not include an articulationjoint. FIGS. 67 and 68 illustrate surgical tools 3200′ and 3200″ thathave end effectors 3212′, 3212″, respectively that may be employed withan elongated shaft embodiment that has an articulation joint of thevarious types disclosed herein. For example, as can be seen in FIG. 64,a threaded closure shaft 3342 is coupled to the proximal end 3223 of theelongated channel 3222 by a flexible cable or other flexible member3345. The location of an articulation joint (not shown) within theelongated shaft assembly 3208 will coincide with the flexible member3345 to enable the flexible member 3345 to accommodate sucharticulation. In addition, in the above-described embodiment, theflexible member 33345 is rotatably affixed to the proximal end portion3223 of the elongated channel 3222 to enable the flexible member 3345 torotate relative thereto to prevent the flexible member 3229 from“winding up” relative to the channel 3222. Although not shown, thecutting element may be driven in one of the above described manners by aknife bar that can also accommodate articulation of the elongated shaftassembly. FIG. 68 depicts a surgical end effector 3212″ that issubstantially identical to the surgical end effector 3212 describedabove, except that the threaded closure rod 3342 is attached to aclosure nut 3347 that is constrained to only move axially within theelongated shaft assembly 3208. The flexible member 3345 is attached tothe closure nut 3347. Such arrangement also prevents the threadedclosure rod 3342 from winding-up the flexible member 3345. A flexibleknife bar 3235′ may be employed to facilitate articulation of thesurgical end effector 3212″.

The surgical tools 3200, 3200′, and 3200″ described above may alsoemploy anyone of the cutting instrument embodiments described herein. Asdescribed above, the anvil of each of the end effectors of these toolsis closed by drawing the elongated channel into contact with the distalend of the elongated shaft assembly. Thus, once the target tissue hasbeen located between the staple cartridge 3234 and the anvil 3224, therobotic controller 1001 can start to draw the channel 3222 inward intothe shaft assembly 3208. In various embodiments, however, to prevent theend effector 3212, 3212′, 3212″ from moving the target tissue with theend effector during this closing process, the controller 1001 maysimultaneously move the tool holder and ultimately the tool such tocompensate for the movement of the elongated channel 3222 so that, ineffect, the target tissue is clamped between the anvil and the elongatedchannel without being otherwise moved.

FIGS. 69-71 depict another surgical tool embodiment 3201 that issubstantially identical to surgical tool 3200″ described above, exceptfor the differences discussed below. In this embodiment, the threadedclosure rod 3342′ has variable pitched grooves. More specifically, ascan be seen in FIG. 70, the closure rod 3342′ has a distal groovesection 3380 and a proximal groove section 3382. The distal and proximalgroove sections 3380, 3382 are configured for engagement with a lug 3390supported within the hollow threaded end portion 3341′. As can be seenin FIG. 70, the distal groove section 3380 has a finer pitch than thegroove section 3382. Thus, such variable pitch arrangement permits theelongated channel 3222 to be drawn into the shaft 3208 at a first speedor rate by virtue of the engagement between the lug 3390 and theproximal groove segment 3382. When the lug 3390 engages the distalgroove segment, the channel 3222 will be drawn into the shaft 3208 at asecond speed or rate. Because the proximal groove segment 3382 iscoarser than the distal groove segment 3380, the first speed will begreater than the second speed. Such arrangement serves to speed up theinitial closing of the end effector for tissue manipulation and thenafter the tissue has been properly positioned therein, generate theamount of closure forces to properly clamp the tissue for cutting andsealing. Thus, the anvil 3234 initially closes fast with a lower forceand then applies a higher closing force as the anvil closes more slowly.

The surgical end effector opening and closing motions are employed toenable the user to use the end effector to grasp and manipulate tissueprior to fully clamping it in the desired location for cutting andsealing. The user may, for example, open and close the surgical endeffector numerous times during this process to orient the end effectorin a proper position which enables the tissue to be held in a desiredlocation. Thus, in at least some embodiments, to produce the highloading for firing, the fine thread may require as many as 5-10 fullrotations to generate the necessary load. In some cases, for example,this action could take as long as 2-5 seconds. If it also took anequally long time to open and close the end effector each time duringthe positioning/tissue manipulation process, just positioning the endeffector may take an undesirably long time. If that happens, it ispossible that a user may abandon such use of the end effector for use ofa conventional grasper device. Use of graspers, etc. may undesirablyincrease the costs associated with completing the surgical procedure.

The above-described embodiments employ a battery or batteries to powerthe motors used to drive the end effector components. Activation of themotors is controlled by the robotic system 1000. In alternativeembodiments, the power supply may comprise alternating current “AC” thatis supplied to the motors by the robotic system 1000. That is, the ACpower would be supplied from the system powering the robotic system 1000through the tool holder and adapter. In still other embodiments, a powercord or tether may be attached to the tool mounting portion 3300 tosupply the requisite power from a separate source of alternating ordirect current.

In use, the controller 1001 may apply an initial rotary motion to theclosure shaft 3340 (FIG. 66) to draw the elongated channel 3222 axiallyinwardly into the elongated shaft assembly 3208 and move the anvil froma first position to an intermediate position at a first rate thatcorresponds with the point wherein the distal groove section 3380transitions to the proximal groove section 3382. Further application ofrotary motion to the closure shaft 3340 will cause the anvil to movefrom the intermediate position to the closed position relative to thesurgical staple cartridge. When in the closed position, the tissue to becut and stapled is properly clamped between the anvil and the surgicalstaple cartridge.

FIGS. 72-75 illustrate another surgical tool embodiment 3400 of thepresent invention. This embodiment includes an elongated shaft assembly3408 that extends from a tool mounting portion 3500. The elongated shaftassembly 3408 includes a rotatable proximal closure tube segment 3410that is rotatably journaled on a proximal spine member 3420 that isrigidly coupled to a tool mounting plate 3502 of the tool mountingportion 3500. The proximal spine member 3420 has a distal end 3422 thatis coupled to an elongated channel portion 3522 of a surgical endeffector 3412. For example, in at least one embodiment, the elongatedchannel portion 3522 has a distal end portion 3523 that “hookinglyengages” the distal end 3422 of the spine member 3420. The elongatedchannel 3522 is configured to support a surgical staple cartridge 3534therein. This embodiment may employ one of the various cuttinginstrument embodiments disclosed herein to sever tissue that is clampedin the surgical end effector 3412 and fire the staples in the staplecartridge 3534 into the severed tissue.

Surgical end effector 3412 has an anvil 3524 that is pivotally coupledto the elongated channel 3522 by a pair of trunnions 3525 that arereceived in corresponding openings 3529 in the elongated channel 3522.The anvil 3524 is moved between the open (FIG. 72) and closed positions(FIGS. 73-75) by a distal closure tube segment 3430. A distal endportion 3432 of the distal closure tube segment 3430 includes an opening3445 into which a tab 3527 on the anvil 3524 is inserted in order toopen and close the anvil 3524 as the distal closure tube segment 3430moves axially relative thereto. In various embodiments, the opening 3445is shaped such that as the closure tube segment 3430 is moved in theproximal direction, the closure tube segment 3430 causes the anvil 3524to pivot to an open position. In addition or in the alternative, aspring (not shown) may be employed to bias the anvil 3524 to the openposition.

As can be seen in FIGS. 72-75, the distal closure tube segment 3430includes a lug 3442 that extends from its distal end 3440 into threadedengagement with a variable pitch groove/thread 3414 formed in the distalend 3412 of the rotatable proximal closure tube segment 3410. Thevariable pitch groove/thread 3414 has a distal section 3416 and aproximal section 3418. The pitch of the distal groove/thread section3416 is finer than the pitch of the proximal groove/thread section 3418.As can also be seen in FIGS. 72-75, the distal closure tube segment 3430is constrained for axial movement relative to the spine member 3420 byan axial retainer pin 3450 that is received in an axial slot 3424 in thedistal end of the spine member 3420.

As indicated above, the anvil 2524 is open and closed by rotating theproximal closure tube segment 3410. The variable pitch threadarrangement permits the distal closure tube segment 3430 to be driven inthe distal direction “DD” at a first speed or rate by virtue of theengagement between the lug 3442 and the proximal groove/thread section3418. When the lug 3442 engages the distal groove/thread section 3416,the distal closure tube segment 3430 will be driven in the distaldirection at a second speed or rate. Because the proximal groove/threadsection 3418 is coarser than the distal groove/thread segment 3416, thefirst speed will be greater than the second speed.

In at least one embodiment, the tool mounting portion 3500 is configuredto receive a corresponding first rotary motion from the roboticcontroller 1001 and convert that first rotary motion to a primary rotarymotion for rotating the rotatable proximal closure tube segment 3410about a longitudinal tool axis LT-LT. As can be seen in FIG. 76, aproximal end 3460 of the proximal closure tube segment 3410 is rotatablysupported within a cradle arrangement 3504 attached to a tool mountingplate 3502 of the tool mounting portion 3500. A rotation gear 3462 isformed on or attached to the proximal end 3460 of the closure tubesegment 3410 for meshing engagement with a rotation drive assembly 3470that is operably supported on the tool mounting plate 3502. In at leastone embodiment, a rotation drive gear 3472 is coupled to a correspondingfirst one of the driven discs or elements 1304 on the adapter side ofthe tool mounting plate 3502 when the tool mounting portion 3500 iscoupled to the tool holder 1270. See FIGS. 34 and 76. The rotation driveassembly 3470 further comprises a rotary driven gear 3474 that isrotatably supported on the tool mounting plate 3502 in meshingengagement with the rotation gear 3462 and the rotation drive gear 3472.Application of a first rotary control motion from the robotic controller1001 through the tool holder 1270 and the adapter 1240 to thecorresponding driven element 1304 will thereby cause rotation of therotation drive gear 3472 by virtue of being operably coupled thereto.Rotation of the rotation drive gear 3472 ultimately results in therotation of the closure tube segment 3410 to open and close the anvil3524 as described above.

As indicated above, the surgical end effector 3412 employs a cuttinginstrument of the type and constructions described above. FIG. 76illustrates one form of knife drive assembly 3480 for axially advancinga knife bar 3492 that is attached to such cutting instrument. One formof the knife drive assembly 3480 comprises a rotary drive gear 3482 thatis coupled to a corresponding third one of the driven discs or elements1304 on the adapter side of the tool mounting plate 3502 when the tooldrive portion 3500 is coupled to the tool holder 1270. See FIGS. 34 and76. The knife drive assembly 3480 further comprises a first rotarydriven gear assembly 3484 that is rotatably supported on the toolmounting plate 5200. The first rotary driven gear assembly 3484 is inmeshing engagement with a third rotary driven gear assembly 3486 that isrotatably supported on the tool mounting plate 3502 and which is inmeshing engagement with a fourth rotary driven gear assembly 3488 thatis in meshing engagement with a threaded portion 3494 of drive shaftassembly 3490 that is coupled to the knife bar 3492. Rotation of therotary drive gear 3482 in a second rotary direction will result in theaxial advancement of the drive shaft assembly 3490 and knife bar 3492 inthe distal direction “DD”. Conversely, rotation of the rotary drive gear3482 in a secondary rotary direction (opposite to the second rotarydirection) will cause the drive shaft assembly 3490 and the knife bar3492 to move in the proximal direction.

FIGS. 77-86 illustrate another surgical tool 3600 embodiment of thepresent invention that may be employed in connection with a roboticsystem 1000. As can be seen in FIG. 77, the tool 3600 includes an endeffector in the form of a disposable loading unit 3612. Various forms ofdisposable loading units that may be employed in connection with tool3600 are disclosed, for example, in U.S. Patent Application PublicationNo. 2009/0206131, entitled END EFFECTOR COUPLING ARRANGEMENTS FOR ASURGICAL CUTTING AND STAPLING INSTRUMENT, the disclosure of which isherein incorporated by reference in its entirety.

In at least one form, the disposable loading unit 3612 includes an anvilassembly 3620 that is supported for pivotal travel relative to a carrier3630 that operably supports a staple cartridge 3640 therein. A mountingassembly 3650 is pivotally coupled to the cartridge carrier 3630 toenable the carrier 3630 to pivot about an articulation axis AA-AArelative to a longitudinal tool axis LT-LT. Referring to FIG. 82,mounting assembly 3650 includes upper and lower mounting portions 3652and 3654. Each mounting portion includes a threaded bore 3656 on eachside thereof dimensioned to receive threaded bolts (not shown) forsecuring the proximal end of carrier 3630 thereto. A pair of centrallylocated pivot members 3658 extends between upper and lower mountingportions via a pair of coupling members 3660 which engage a distal endof a housing portion 3662. Coupling members 3660 each include aninterlocking proximal portion 3664 configured to be received in grooves3666 formed in the proximal end of housing portion 3662 to retainmounting assembly 3650 and housing portion 3662 in a longitudinallyfixed position in relation thereto.

In various forms, housing portion 3662 of disposable loading unit 3614includes an upper housing half 3670 and a lower housing half 3672contained within an outer casing 3674. The proximal end of housing half3670 includes engagement nubs 3676 for releasably engaging an elongatedshaft 3700 and an insertion tip 3678. Nubs 3676 form a bayonet-typecoupling with the distal end of the elongated shaft 3700 which will bediscussed in further detail below. Housing halves 3670, 3672 define achannel 3674 for slidably receiving axial drive assembly 3680. A secondarticulation link 3690 is dimensioned to be slidably positioned within aslot 3679 formed between housing halves 3670, 3672. A pair of blow outplates 3691 are positioned adjacent the distal end of housing portion3662 adjacent the distal end of axial drive assembly 3680 to preventoutward bulging of drive assembly 3680 during articulation of carrier3630.

In various embodiments, the second articulation link 3690 includes atleast one elongated metallic plate. Preferably, two or more metallicplates are stacked to form link 3690. The proximal end of articulationlink 3690 includes a hook portion 3692 configured to engage firstarticulation link 3710 extending through the elongated shaft 3700. Thedistal end of the second articulation link 3690 includes a loop 3694dimensioned to engage a projection formed on mounting assembly 3650. Theprojection is laterally offset from pivot pin 3658 such that linearmovement of second articulation link 3690 causes mounting assembly 3650to pivot about pivot pins 3658 to articulate the carrier 3630.

In various forms, axial drive assembly 3680 includes an elongated drivebeam 3682 including a distal working head 3684 and a proximal engagementsection 3685. Drive beam 3682 may be constructed from a single sheet ofmaterial or, preferably, multiple stacked sheets. Engagement section3685 includes a pair of engagement fingers which are dimensioned andconfigured to mountingly engage a pair of corresponding retention slotsformed in drive member 3686. Drive member 3686 includes a proximalporthole 3687 configured to receive the distal end 3722 of control rod2720 (See FIG. 86) when the proximal end of disposable loading unit 3614is engaged with elongated shaft 3700 of surgical tool 3600.

Referring to FIGS. 77 and 84-86, to use the surgical tool 3600, adisposable loading unit 3612 is first secured to the distal end ofelongated shaft 3700. It will be appreciated that the surgical tool 3600may include an articulating or a non-articulating disposable loadingunit. To secure the disposable loading unit 3612 to the elongated shaft3700, the distal end 3722 of control rod 3720 is inserted into insertiontip 3678 of disposable loading unit 3612, and insertion tip 3678 is slidlongitudinally into the distal end of the elongated shaft 3700 in thedirection indicated by arrow “A” in FIG. 84 such that hook portion 3692of second articulation link 3690 slides within a channel 3702 in theelongated shaft 3700. Nubs 3676 will each be aligned in a respectivechannel (not shown) in elongated shaft 3700. When hook portion 3692engages the proximal wall 3704 of channel 3702, disposable loading unit3612 is rotated in the direction indicated by arrow “B” in FIGS. 83 and84 to move hook portion 3692 of second articulation link 3690 intoengagement with finger 3712 of first articulation link 3710. Nubs 3676also form a “bayonet-type” coupling within annular channel 3703 in theelongated shaft 3700. During rotation of loading unit 3612, nubs 3676engage cam surface 3732 (FIG. 84) of block plate 3730 to initially moveplate 3730 in the direction indicated by arrow “C” in FIG. 84 to lockengagement member 3734 in recess 3721 of control rod 3720 to preventlongitudinal movement of control rod 3720 during attachment ofdisposable loading unit 3612. During the final degree of rotation, nubs3676 disengage from cam surface 3732 to allow blocking plate 3730 tomove in the direction indicated by arrow “D” in FIGS. 83 and 86 frombehind engagement member 3734 to once again permit longitudinal movementof control rod 3720. While the above-described attachment methodreflects that the disposable loading unit 3612 is manipulated relativeto the elongated shaft 3700, the person of ordinary skill in the artwill appreciate that the disposable loading unit 3612 may be supportedin a stationary position and the robotic system 1000 may manipulate theelongated shaft portion 3700 relative to the disposable loading unit3612 to accomplish the above-described coupling procedure.

FIG. 87 illustrates another disposable loading unit 3612′ that isattachable in a bayonet-type arrangement with the elongated shaft 3700′that is substantially identical to shaft 3700 except for the differencesdiscussed below. As can be seen in FIG. 87, the elongated shaft 3700′has slots 3705 that extend for at least a portion thereof and which areconfigured to receive nubs 3676 therein. In various embodiments, thedisposable loading unit 3612′ includes arms 3677 extending therefromwhich, prior to the rotation of disposable loading unit 3612′, can bealigned, or at least substantially aligned, with nubs 3676 extendingfrom housing portion 3662. In at least one embodiment, arms 3677 andnubs 3676 can be inserted into slots 3705 in elongated shaft 3700′, forexample, when disposable loading unit 3612′ is inserted into elongatedshaft 3700′. When disposable loading unit 3612′ is rotated, arms 3677can be sufficiently confined within slots 3705 such that slots 3705 canhold them in position, whereas nubs 3676 can be positioned such thatthey are not confined within slots 3705 and can be rotated relative toarms 3677. When rotated, the hook portion 3692 of the articulation link3690 is engaged with the first articulation link 3710 extending throughthe elongated shaft 3700′.

Other methods of coupling the disposable loading units to the end of theelongated shaft may be employed. For example, as shown in FIGS. 88 and89, disposable loading unit 3612″ can include connector portion 3613which can be configured to be engaged with connector portion 3740 of theelongated shaft 3700″. In at least one embodiment, connector portion3613 can include at least one projection and/or groove which can bemated with at least one projection and/or groove of connector portion3740. In at least one such embodiment, the connector portions caninclude co-operating dovetail portions. In various embodiments, theconnector portions can be configured to interlock with one another andprevent, or at least inhibit, distal and/or proximal movement ofdisposable loading unit 3612″ along axis 3741. In at least oneembodiment, the distal end of the axial drive assembly 3680′ can includeaperture 3681 which can be configured to receive projection 3721extending from control rod 3720′. In various embodiments, such anarrangement can allow disposable loading unit 3612″ to be assembled toelongated shaft 3700 in a direction which is not collinear with orparallel to axis 3741. Although not illustrated, axial drive assembly3680′ and control rod 3720 can include any other suitable arrangement ofprojections and apertures to operably connect them to each other. Alsoin this embodiment, the first articulation link 3710 which can beoperably engaged with second articulation link 3690.

As can be seen in FIGS. 77 and 90, the surgical tool 3600 includes atool mounting portion 3750. The tool mounting portion 3750 includes atool mounting plate 3751 that is configured for attachment to the tooldrive assembly 1010. The tool mounting portion operably supported atransmission arrangement 3752 thereon. In use, it may be desirable torotate the disposable loading unit 3612 about the longitudinal tool axisdefined by the elongated shaft 3700. In at least one embodiment, thetransmission arrangement 3752 includes a rotational transmissionassembly 3753 that is configured to receive a corresponding rotaryoutput motion from the tool drive assembly 1010 of the robotic system1000 and convert that rotary output motion to a rotary control motionfor rotating the elongated shaft 3700 (and the disposable loading unit3612) about the longitudinal tool axis LT-LT. As can be seen in FIG. 90,a proximal end 3701 of the elongated shaft 3700 is rotatably supportedwithin a cradle arrangement 3754 that is attached to the tool mountingplate 3751 of the tool mounting portion 3750. A rotation gear 3755 isformed on or attached to the proximal end 3701 of the elongated shaft3700 for meshing engagement with a rotation gear assembly 3756 operablysupported on the tool mounting plate 3751. In at least one embodiment, arotation drive gear 3757 drivingly coupled to a corresponding first oneof the driven discs or elements 1304 on the adapter side of the toolmounting plate 3751 when the tool mounting portion 3750 is coupled tothe tool drive assembly 1010. The rotation transmission assembly 3753further comprises a rotary driven gear 3758 that is rotatably supportedon the tool mounting plate 3751 in meshing engagement with the rotationgear 3755 and the rotation drive gear 3757. Application of a firstrotary output motion from the robotic system 1000 through the tool driveassembly 1010 to the corresponding driven element 1304 will therebycause rotation of the rotation drive gear 3757 by virtue of beingoperably coupled thereto. Rotation of the rotation drive gear 3757ultimately results in the rotation of the elongated shaft 3700 (and thedisposable loading unit 3612) about the longitudinal tool axis LT-LT(primary rotary motion).

As can be seen in FIG. 90, a drive shaft assembly 3760 is coupled to aproximal end of the control rod 2720. In various embodiments, thecontrol rod 2720 is axially advanced in the distal and proximaldirections by a knife/closure drive transmission 3762. One form of theknife/closure drive assembly 3762 comprises a rotary drive gear 3763that is coupled to a corresponding second one of the driven rotatablebody portions, discs or elements 1304 on the adapter side of the toolmounting plate 3751 when the tool mounting portion 3750 is coupled tothe tool holder 1270. The rotary driven gear 3763 is in meshing drivingengagement with a gear train, generally depicted as 3764. In at leastone form, the gear train 3764 further comprises a first rotary drivengear assembly 3765 that is rotatably supported on the tool mountingplate 3751. The first rotary driven gear assembly 3765 is in meshingengagement with a second rotary driven gear assembly 3766 that isrotatably supported on the tool mounting plate 3751 and which is inmeshing engagement with a third rotary driven gear assembly 3767 that isin meshing engagement with a threaded portion 3768 of the drive shaftassembly 3760. Rotation of the rotary drive gear 3763 in a second rotarydirection will result in the axial advancement of the drive shaftassembly 3760 and control rod 2720 in the distal direction “DD”.Conversely, rotation of the rotary drive gear 3763 in a secondary rotarydirection which is opposite to the second rotary direction will causethe drive shaft assembly 3760 and the control rod 2720 to move in theproximal direction. When the control rod 2720 moves in the distaldirection, it drives the drive beam 3682 and the working head 3684thereof distally through the surgical staple cartridge 3640. As theworking head 3684 is driven distally, it operably engages the anvil 3620to pivot it to a closed position.

The cartridge carrier 3630 may be selectively articulated aboutarticulation axis AA-AA by applying axial articulation control motionsto the first and second articulation links 3710 and 3690. In variousembodiments, the transmission arrangement 3752 further includes anarticulation drive 3770 that is operably supported on the tool mountingplate 3751. More specifically and with reference to FIG. 90, it can beseen that a proximal end portion 3772 of an articulation drive shaft3771 configured to operably engage with the first articulation link 3710extends through the rotation gear 3755 and is rotatably coupled to ashifter rack gear 3774 that is slidably affixed to the tool mountingplate 3751 through slots 3775. The articulation drive 3770 furthercomprises a shifter drive gear 3776 that is coupled to a correspondingthird one of the driven discs or elements 1304 on the adapter side ofthe tool mounting plate 3751 when the tool mounting portion 3750 iscoupled to the tool holder 1270. The articulation drive assembly 3770further comprises a shifter driven gear 3778 that is rotatably supportedon the tool mounting plate 3751 in meshing engagement with the shifterdrive gear 3776 and the shifter rack gear 3774. Application of a thirdrotary output motion from the robotic system 1000 through the tool driveassembly 1010 to the corresponding driven element 1304 will therebycause rotation of the shifter drive gear 3776 by virtue of beingoperably coupled thereto. Rotation of the shifter drive gear 3776ultimately results in the axial movement of the shifter gear rack 3774and the articulation drive shaft 3771. The direction of axial travel ofthe articulation drive shaft 3771 depends upon the direction in whichthe shifter drive gear 3776 is rotated by the robotic system 1000. Thus,rotation of the shifter drive gear 3776 in a first rotary direction willresult in the axial movement of the articulation drive shaft 3771 in theproximal direction “PD” and cause the cartridge carrier 3630 to pivot ina first direction about articulation axis AA-AA. Conversely, rotation ofthe shifter drive gear 3776 in a second rotary direction (opposite tothe first rotary direction) will result in the axial movement of thearticulation drive shaft 3771 in the distal direction “DD” to therebycause the cartridge carrier 3630 to pivot about articulation axis AA-AAin an opposite direction.

FIG. 91 illustrates yet another surgical tool 3800 embodiment of thepresent invention that may be employed with a robotic system 1000. Ascan be seen in FIG. 91, the surgical tool 3800 includes a surgical endeffector 3812 in the form of an endocutter 3814 that employs variouscable-driven components. Various forms of cable driven endocutters aredisclosed, for example, in U.S. Pat. No. 7,726,537, entitled SURGICALSTAPLER WITH UNIVERSAL ARTICULATION AND TISSUE PRE-CLAMP and U.S. PatentApplication Publication No. 2008/0308603, entitled CABLE DRIVEN SURGICALSTAPLING AND CUTTING INSTRUMENT WITH IMPROVED CABLE ATTACHMENTARRANGEMENTS, the disclosures of each are herein incorporated byreference in their respective entireties. Such endocutters 3814 may bereferred to as a “disposable loading unit” because they are designed tobe disposed of after a single use. However, the various unique and novelarrangements of various embodiments of the present invention may also beemployed in connection with cable driven end effectors that arereusable.

As can be seen in FIG. 91, in at least one form, the endocutter 3814includes an elongated channel 3822 that operably supports a surgicalstaple cartridge 3834 therein. An anvil 3824 is pivotally supported formovement relative to the surgical staple cartridge 3834. The anvil 3824has a cam surface 3825 that is configured for interaction with apreclamping collar 3840 that is supported for axial movement relativethereto. The end effector 3814 is coupled to an elongated shaft assembly3808 that is attached to a tool mounting portion 3900. In variousembodiments, a closure cable 3850 is employed to move pre-clampingcollar 3840 distally onto and over cam surface 3825 to close the anvil3824 relative to the surgical staple cartridge 3834 and compress thetissue therebetween. Preferably, closure cable 3850 attaches to thepre-clamping collar 3840 at or near point 3841 and is fed through apassageway in anvil 3824 (or under a proximal portion of anvil 3824) andfed proximally through shaft 3808. Actuation of closure cable 3850 inthe proximal direction “PD” forces pre-clamping collar 3840 distallyagainst cam surface 3825 to close anvil 3824 relative to staplecartridge assembly 3834. A return mechanism, e.g., a spring, cablesystem or the like, may be employed to return pre-clamping collar 3840to a pre-clamping orientation which re-opens the anvil 3824.

The elongated shaft assembly 3808 may be cylindrical in shape and definea channel 3811 which may be dimensioned to receive a tube adapter 3870.See FIG. 92. In various embodiments, the tube adapter 3870 may beslidingly received in friction-fit engagement with the internal channelof elongated shaft 3808. The outer surface of the tube adapter 3870 mayfurther include at least one mechanical interface, e.g., a cutout ornotch 3871, oriented to mate with a corresponding mechanical interface,e.g., a radially inwardly extending protrusion or detent (not shown),disposed on the inner periphery of internal channel 3811 to lock thetube adapter 3870 to the elongated shaft 3808. In various embodiments,the distal end of tube adapter 3870 may include a pair of opposingflanges 3872 a and 3872 b which define a cavity for pivotably receivinga pivot block 3873 therein. Each flange 3872 a and 3872 b may include anaperture 3874 a and 3874 b that is oriented to receive a pivot pin 3875that extends through an aperture in pivot block 3873 to allow pivotablemovement of pivot block 3873 about an axis that is perpendicular tolongitudinal tool axis “LT-LT”. The channel 3822 may be formed with twoupwardly extending flanges 3823 a, 3823 b that have apertures therein,which are dimensioned to receive a pivot pin 3827. In turn, pivot pin3875 mounts through apertures in pivot block 3873 to permit rotation ofthe surgical end effector 3814 about the “Y” axis as needed during agiven surgical procedure. Rotation of pivot block 3873 about pin 3875along “Z” axis rotates the surgical end effector 3814 about the “Z”axis. See FIG. 92. Other methods of fastening the elongated channel 3822to the pivot block 3873 may be effectively employed without departingfrom the spirit and scope of the present invention.

The surgical staple cartridge 3834 can be assembled and mounted withinthe elongated channel 3822 during the manufacturing or assembly processand sold as part of the surgical end effector 3812, or the surgicalstaple cartridge 3834 may be designed for selective mounting within theelongated channel 3822 as needed and sold separately, e.g., as a singleuse replacement, replaceable or disposable staple cartridge assembly. Itis within the scope of this disclosure that the surgical end effector3812 may be pivotally, operatively, or integrally attached, for example,to distal end 3809 of the elongated shaft assembly 3808 of a disposablesurgical stapler. As is known, a used or spent disposable loading unit3814 can be removed from the elongated shaft assembly 3808 and replacedwith an unused disposable unit. The endocutter 3814 may also preferablyinclude an actuator, preferably a dynamic clamping member 3860, a sled3862, as well as staple pushers (not shown) and staples (not shown) oncean unspent or unused cartridge 3834 is mounted in the elongated channel3822. See FIG.

In various embodiments, the dynamic clamping member 3860 is associatedwith, e.g., mounted on and rides on, or with or is connected to orintegral with and/or rides behind sled 3862. It is envisioned thatdynamic clamping member 3860 can have cam wedges or cam surfacesattached or integrally formed or be pushed by a leading distal surfacethereof. In various embodiments, dynamic clamping member 3860 mayinclude an upper portion 3863 having a transverse aperture 3864 with apin 3865 mountable or mounted therein, a central support or upwardextension 3866 and substantially T-shaped bottom flange 3867 whichcooperate to slidingly retain dynamic clamping member 3860 along anideal cutting path during longitudinal, distal movement of sled 3862.The leading cutting edge 3868, here, knife blade 3869, is dimensioned toride within slot 3835 of staple cartridge assembly 3834 and separatetissue once stapled. As used herein, the term “knife assembly” mayinclude the aforementioned dynamic clamping member 3860, knife 3869, andsled 3862 or other knife/beam/sled drive arrangements and cuttinginstrument arrangements. In addition, the various embodiments of thepresent invention may be employed with knife assembly/cutting instrumentarrangements that may be entirely supported in the staple cartridge 3834or partially supported in the staple cartridge 3834 and elongatedchannel 3822 or entirely supported within the elongated channel 3822.

In various embodiments, the dynamic clamping member 3860 may be drivenin the proximal and distal directions by a cable drive assembly 3870. Inone non-limiting form, the cable drive assembly comprises a pair ofadvance cables 3880, 3882 and a firing cable 3884. FIGS. 93 and 94illustrate the cables 3880, 3882, 3884 in diagrammatic form. As can beseen in those Figures, a first advance cable 3880 is operably supportedon a first distal cable transition support 3885 which may comprise, forexample, a pulley, rod, capstan, etc. that is attached to the distal endof the elongated channel 3822 and a first proximal cable transitionsupport 3886 which may comprise, for example, a pulley, rod, capstan,etc. that is operably supported by the elongated channel 3822. A distalend 3881 of the first advance cable 3880 is affixed to the dynamicclamping assembly 3860. The second advance cable 3882 is operablysupported on a second distal cable transition support 3887 which may,for example, comprise a pulley, rod, capstan etc. that is mounted to thedistal end of the elongated channel 3822 and a second proximal cabletransition support 3888 which may, for example, comprise a pulley, rod,capstan, etc. mounted to the proximal end of the elongated channel 3822.The proximal end 3883 of the second advance cable 3882 may be attachedto the dynamic clamping assembly 3860. Also in these embodiments, anendless firing cable 3884 is employed and journaled on a support 3889that may comprise a pulley, rod, capstan, etc. mounted within theelongated shaft 3808. In one embodiment, the retract cable 3884 may beformed in a loop and coupled to a connector 3889′ that is fixedlyattached to the first and second advance cables 3880, 3882.

Various non-limiting embodiments of the present invention include acable drive transmission 3920 that is operably supported on a toolmounting plate 3902 of the tool mounting portion 3900. The tool mountingportion 3900 has an array of electrical connecting pins 3904 which areconfigured to interface with the slots 1258 (FIG. 33) in the adapter1240′. Such arrangement permits the robotic system 1000 to providecontrol signals to a control circuit 3910 of the tool 3800. While theinterface is described herein with reference to mechanical, electrical,and magnetic coupling elements, it should be understood that a widevariety of telemetry modalities might be used, including infrared,inductive coupling, or the like.

Control circuit 3910 is shown in schematic form in FIG. 91. In one formor embodiment, the control circuit 3910 includes a power supply in theform of a battery 3912 that is coupled to an on-off solenoid poweredswitch 3914. In other embodiments, however, the power supply maycomprise a source of alternating current. Control circuit 3910 furtherincludes an on/off solenoid 3916 that is coupled to a double pole switch3918 for controlling motor rotation direction. Thus, when the roboticsystem 1000 supplies an appropriate control signal, switch 3914 willpermit battery 3912 to supply power to the double pole switch 3918. Therobotic system 1000 will also supply an appropriate signal to the doublepole switch 3918 to supply power to a shifter motor 3922.

Turning to FIGS. 95-100, at least one embodiment of the cable drivetransmission 3920 comprises a drive pulley 3930 that is operably mountedto a drive shaft 3932 that is attached to a driven element 1304 of thetype and construction described above that is designed to interface witha corresponding drive element 1250 of the adapter 1240. See FIGS. 33 and98. Thus, when the tool mounting portion 3900 is operably coupled to thetool holder 1270, the robot system 1000 can apply rotary motion to thedrive pulley 3930 in a desired direction. A first drive member or belt3934 drivingly engages the drive pulley 3930 and a second drive shaft3936 that is rotatably supported on a shifter yoke 3940. The shifteryoke 3940 is operably coupled to the shifter motor 3922 such thatrotation of the shaft 3923 of the shifter motor 3922 in a firstdirection will shift the shifter yoke in a first direction “FD” androtation of the shifter motor shaft 3923 in a second direction willshift the shifter yoke 3940 in a second direction “SD”. Otherembodiments of the present invention may employ a shifter solenoidarrangement for shifting the shifter yoke in said first and seconddirections.

As can be seen in FIGS. 95-98, a closure drive gear 3950 mounted to asecond drive shaft 3936 and is configured to selectively mesh with aclosure drive assembly, generally designated as 3951. Likewise a firingdrive gear 3960 is also mounted to the second drive shaft 3936 and isconfigured to selectively mesh with a firing drive assembly generallydesignated as 3961. Rotation of the second drive shaft 3936 causes theclosure drive gear 3950 and the firing drive gear 3960 to rotate. In onenon-limiting embodiment, the closure drive assembly 3951 comprises aclosure driven gear 3952 that is coupled to a first closure pulley 3954that is rotatably supported on a third drive shaft 3956. The closurecable 3850 is drivingly received on the first closure pulley 3954 suchthat rotation of the closure driven gear 3952 will drive the closurecable 3850. Likewise, the firing drive assembly 3961 comprises a firingdriven gear 3962 that is coupled to a first firing pulley 3964 that isrotatably supported on the third drive shaft 3956. The first and seconddriving pulleys 3954 and 3964 are independently rotatable on the thirddrive shaft 3956. The firing cable 3884 is drivingly received on thefirst firing pulley 3964 such that rotation of the firing driven gear3962 will drive the firing cable 3884.

Also in various embodiments, the cable drive transmission 3920 furtherincludes a braking assembly 3970. In at least one embodiment, forexample, the braking assembly 3970 includes a closure brake 3972 thatcomprises a spring arm 3973 that is attached to a portion of thetransmission housing 3971. The closure brake 3972 has a gear lug 3974that is sized to engage the teeth of the closure driven gear 3952 aswill be discussed in further detail below. The braking assembly 3970further includes a firing brake 3976 that comprises a spring arm 3977that is attached to another portion of the transmission housing 3971.The firing brake 3976 has a gear lug 3978 that is sized to engage theteeth of the firing driven gear 3962.

At least one embodiment of the surgical tool 3800 may be used asfollows. The tool mounting portion 3900 is operably coupled to theinterface 1240 of the robotic system 1000. The controller or controlunit of the robotic system is operated to locate the tissue to be cutand stapled between the open anvil 3824 and the staple cartridge 3834.When in that initial position, the braking assembly 3970 has locked theclosure driven gear 3952 and the firing driven gear 3962 such that theycannot rotate. That is, as shown in FIG. 96, the gear lug 3974 is inlocking engagement with the closure driven gear 3952 and the gear lug3978 is in locking engagement with the firing driven gear 3962. Once thesurgical end effector 3814 has been properly located, the controller1001 of the robotic system 1000 will provide a control signal to theshifter motor 3922 (or shifter solenoid) to move the shifter yoke 3940in the first direction. As the shifter yoke 3940 is moved in the firstdirection, the closure drive gear 3950 moves the gear lug 3974 out ofengagement with the closure driven gear 3952 as it moves into meshingengagement with the closure driven gear 3952. As can be seen in FIG. 95,when in that position, the gear lug 3978 remains in locking engagementwith the firing driven gear 3962 to prevent actuation of the firingsystem. Thereafter, the robotic controller 1001 provides a first rotaryactuation motion to the drive pulley 3930 through the interface betweenthe driven element 1304 and the corresponding components of the toolholder 1240. As the drive pulley 3930 is rotated in the first direction,the closure cable 3850 is rotated to drive the preclam ping collar 3840into closing engagement with the cam surface 3825 of the anvil 3824 tomove it to the closed position thereby clamping the target tissuebetween the anvil 3824 and the staple cartridge 3834. See FIG. 91. Oncethe anvil 3824 has been moved to the closed position, the roboticcontroller 1001 stops the application of the first rotary motion to thedrive pulley 3930. Thereafter, the robotic controller 1001 may commencethe firing process by sending another control signal to the shiftermotor 3922 (or shifter solenoid) to cause the shifter yoke to move inthe second direction “SD” as shown in FIG. 97. As the shifter yoke 3940is moved in the second direction, the firing drive gear 3960 moves thegear lug 3978 out of engagement with the firing driven gear 3962 as itmoves into meshing engagement with the firing driven gear 3962. As canbe seen in FIG. 97, when in that position, the gear lug 3974 remains inlocking engagement with the closure driven gear 3952 to preventactuation of the closure system. Thereafter, the robotic controller 1001is activated to provide the first rotary actuation motion to the drivepulley 3930 through the interface between the driven element 1304 andthe corresponding components of the tool holder 1240. As the drivepulley 3930 is rotated in the first direction, the firing cable 3884 isrotated to drive the dynamic clamping member 3860 in the distaldirection “DD” thereby firing the stapes and cutting the tissue clampedin the end effector 3814. Once the robotic system 1000 determines thatthe dynamic clamping member 3860 has reached its distal mostposition—either through sensors or through monitoring the amount ofrotary input applied to the drive pulley 3930, the controller 1001 maythen apply a second rotary motion to the drive pulley 3930 to rotate theclosure cable 3850 in an opposite direction to cause the dynamicclamping member 3860 to be retracted in the proximal direction “PD”.Once the dynamic clamping member has been retracted to the startingposition, the application of the second rotary motion to the drivepulley 3930 is discontinued. Thereafter, the shifter motor 3922 (orshifter solenoid) is powered to move the shifter yoke 3940 to theclosure position (FIG. 95). Once the closure drive gear 3950 is inmeshing engagement with the closure driven gear 3952, the roboticcontroller 1001 may once again apply the second rotary motion to thedrive pulley 3930. Rotation of the drive pulley 3930 in the seconddirection causes the closure cable 3850 to retract the preclampingcollar 3840 out of engagement with the cam surface 3825 of the anvil3824 to permit the anvil 3824 to move to an open position (by a springor other means) to release the stapled tissue from the surgical endeffector 3814.

FIG. 101 illustrates a surgical tool 4000 that employs a gear drivenfiring bar 4092 as shown in FIGS. 102-104. This embodiment includes anelongated shaft assembly 4008 that extends from a tool mounting portion4100. The tool mounting portion 4100 includes a tool mounting plate 4102that operable supports a transmission arrangement 4103 thereon. Theelongated shaft assembly 4008 includes a rotatable proximal closure tube4010 that is rotatably journaled on a proximal spine member 4020 that isrigidly coupled to the tool mounting plate 4102. The proximal spinemember 4020 has a distal end that is coupled to an elongated channelportion 4022 of a surgical end effector 4012. The surgical effector 4012may be substantially similar to surgical end effector 3412 describedabove. In addition, the anvil 4024 of the surgical end effector 4012 maybe opened and closed by a distal closure tube 4030 that operablyinterfaces with the proximal closure tube 4010. Distal closure tube 4030is identical to distal closure tube 3430 described above. Similarly,proximal closure tube 4010 is identical to proximal closure tube segment3410 described above.

Anvil 4024 is opened and closed by rotating the proximal closure tube4010 in manner described above with respect to distal closure tube 3410.In at least one embodiment, the transmission arrangement comprises aclosure transmission, generally designated as 4011. As will be furtherdiscussed below, the closure transmission 4011 is configured to receivea corresponding first rotary motion from the robotic system 1000 andconvert that first rotary motion to a primary rotary motion for rotatingthe rotatable proximal closure tube 4010 about the longitudinal toolaxis LT-LT. As can be seen in FIG. 104, a proximal end 4060 of theproximal closure tube 4010 is rotatably supported within a cradlearrangement 4104 that is attached to a tool mounting plate 4102 of thetool mounting portion 4100. A rotation gear 4062 is formed on orattached to the proximal end 4060 of the closure tube segment 4010 formeshing engagement with a rotation drive assembly 4070 that is operablysupported on the tool mounting plate 4102. In at least one embodiment, arotation drive gear 4072 is coupled to a corresponding first one of thedriven discs or elements 1304 on the adapter side of the tool mountingplate 4102 when the tool mounting portion 4100 is coupled to the toolholder 1270. See FIGS. 34 and 104. The rotation drive assembly 4070further comprises a rotary driven gear 4074 that is rotatably supportedon the tool mounting plate 4102 in meshing engagement with the rotationgear 4062 and the rotation drive gear 4072. Application of a firstrotary control motion from the robotic system 1000 through the toolholder 1270 and the adapter 1240 to the corresponding driven element1304 will thereby cause rotation of the rotation drive gear 4072 byvirtue of being operably coupled thereto. Rotation of the rotation drivegear 4072 ultimately results in the rotation of the closure tube segment4010 to open and close the anvil 4024 as described above.

As indicated above, the end effector 4012 employs a cutting element 3860as shown in FIGS. 102 and 103. In at least one non-limiting embodiment,the transmission arrangement 4103 further comprises a knife drivetransmission that includes a knife drive assembly 4080. FIG. 104illustrates one form of knife drive assembly 4080 for axially advancingthe knife bar 4092 that is attached to such cutting element using cablesas described above with respect to surgical tool 3800. In particular,the knife bar 4092 replaces the firing cable 3884 employed in anembodiment of surgical tool 3800. One form of the knife drive assembly4080 comprises a rotary drive gear 4082 that is coupled to acorresponding second one of the driven discs or elements 1304 on theadapter side of the tool mounting plate 4102 when the tool mountingportion 4100 is coupled to the tool holder 1270. See FIGS. 34 and 104.The knife drive assembly 4080 further comprises a first rotary drivengear assembly 4084 that is rotatably supported on the tool mountingplate 4102. The first rotary driven gear assembly 4084 is in meshingengagement with a third rotary driven gear assembly 4086 that isrotatably supported on the tool mounting plate 4102 and which is inmeshing engagement with a fourth rotary driven gear assembly 4088 thatis in meshing engagement with a threaded portion 4094 of drive shaftassembly 4090 that is coupled to the knife bar 4092. Rotation of therotary drive gear 4082 in a second rotary direction will result in theaxial advancement of the drive shaft assembly 4090 and knife bar 4092 inthe distal direction “DD”. Conversely, rotation of the rotary drive gear4082 in a secondary rotary direction (opposite to the second rotarydirection) will cause the drive shaft assembly 4090 and the knife bar4092 to move in the proximal direction. Movement of the firing bar 4092in the proximal direction “PD” will drive the cutting element 3860 inthe distal direction “DD”. Conversely, movement of the firing bar 4092in the distal direction “DD” will result in the movement of the cuttingelement 3860 in the proximal direction “PD”.

FIGS. 105-111 illustrate yet another surgical tool 5000 that may beeffectively employed in connection with a robotic system 1000. Invarious forms, the surgical tool 5000 includes a surgical end effector5012 in the form of a surgical stapling instrument that includes anelongated channel 5020 and a pivotally translatable clamping member,such as an anvil 5070, which are maintained at a spacing that assureseffective stapling and severing of tissue clamped in the surgical endeffector 5012. As can be seen in FIG. 107, the elongated channel 5020may be substantially U-shaped in cross-section and be fabricated from,for example, titanium, 203 stainless steel, 304 stainless steel, 416stainless steel, 17-4 stainless steel, 17-7 stainless steel, 6061 or7075 aluminum, chromium steel, ceramic, etc. A substantially U-shapedmetal channel pan 5022 may be supported in the bottom of the elongatedchannel 5020 as shown.

Various embodiments include an actuation member in the form of a sledassembly 5030 that is operably supported within the surgical endeffector 5012 and axially movable therein between a staring position andan ending position in response to control motions applied thereto. Insome forms, the metal channel pan 5022 has a centrally-disposed slot5024 therein to movably accommodate a base portion 5032 of the sledassembly 5030. The base portion 5032 includes a foot portion 5034 thatis sized to be slidably received in a slot 5021 in the elongated channel5020. See FIG. 107. As can be seen in FIGS. 107, 110, and 111, the baseportion 5032 of sled assembly 5030 includes an axially extendingthreaded bore 5036 that is configured to be threadedly received on athreaded drive shaft 5130 as will be discussed in further detail below.In addition, the sled assembly 5030 includes an upstanding supportportion 5038 that supports a tissue cutting blade or tissue cuttinginstrument 5040. The upstanding support portion 5038 terminates in a topportion 5042 that has a pair of laterally extending retaining fins 5044protruding therefrom. As shown in FIG. 107, the fins 5044 are positionedto be received within corresponding slots 5072 in anvil 5070. The fins5044 and the foot 5034 serve to retain the anvil 5070 in a desiredspaced closed position as the sled assembly 5030 is driven distallythrough the tissue clamped within the surgical end effector 5014. As canalso be seen in FIGS. 109 and 111, the sled assembly 5030 furtherincludes a reciprocatably or sequentially activatable drive assembly5050 for driving staple pushers toward the closed anvil 5070.

More specifically and with reference to FIGS. 107 and 108, the elongatedchannel 5020 is configured to operably support a surgical staplecartridge 5080 therein. In at least one form, the surgical staplecartridge 5080 comprises a body portion 5082 that may be fabricatedfrom, for example, Vectra, Nylon (6/6 or 6/12) and include a centrallydisposed slot 5084 for accommodating the upstanding support portion 5038of the sled assembly 5030. See FIG. 107. These materials could also befilled with glass, carbon, or mineral fill of 10%-40%. The surgicalstaple cartridge 5080 further includes a plurality of cavities 5086 formovably supporting lines or rows of staple-supporting pushers 5088therein. The cavities 5086 may be arranged in spaced longitudinallyextending lines or rows 5090, 5092, 5094, 5096. For example, the rows5090 may be referred to herein as first outboard rows. The rows 5092 maybe referred to herein as first inboard rows. The rows 5094 may bereferred to as second inboard rows and the rows 5096 may be referred toas second outboard rows. The first inboard row 5090 and the firstoutboard row 5092 are located on a first lateral side of thelongitudinal slot 5084 and the second inboard row 5094 and the secondoutboard row 5096 are located on a second lateral side of thelongitudinal slot 5084. The first staple pushers 5088 in the firstinboard row 5092 are staggered in relationship to the first staplepushers 5088 in the first outboard row 5090. Similarly, the secondstaple pushers 5088 in the second outboard row 5096 are staggered inrelationship to the second pushers 5088 in the second inboard row 5094.Each pusher 5088 operably supports a surgical staple 5098 thereon.

In various embodiments, the sequentially-activatable orreciprocatably-activatable drive assembly 5050 includes a pair ofoutboard drivers 5052 and a pair of inboard drivers 5054 that are eachattached to a common shaft 5056 that is rotatably mounted within thebase 5032 of the sled assembly 5030. The outboard drivers 5052 areoriented to sequentially or reciprocatingly engage a correspondingplurality of outboard activation cavities 5026 provided in the channelpan 5022. Likewise, the inboard drivers 5054 are oriented tosequentially or reciprocatingly engage a corresponding plurality ofinboard activation cavities 5028 provided in the channel pan 5022. Theinboard activation cavities 5028 are arranged in a staggeredrelationship relative to the adjacent outboard activation cavities 5026.See FIG. 108. As can also be seen in FIGS. 108 and 110, in at least oneembodiment, the sled assembly 5030 further includes distal wedgesegments 5060 and intermediate wedge segments 5062 located on each sideof the bore 5036 to engage the pushers 5088 as the sled assembly 5030 isdriven distally in the distal direction “DD”. As indicated above, thesled assembly 5030 is threadedly received on a threaded portion 5132 ofa drive shaft 5130 that is rotatably supported within the end effector5012. In various embodiments, for example, the drive shaft 5130 has adistal end 5134 that is supported in a distal bearing 5136 mounted inthe surgical end effector 5012. See FIGS. 107 and 108.

In various embodiments, the surgical end effector 5012 is coupled to atool mounting portion 5200 by an elongated shaft assembly 5108. In atleast one embodiment, the tool mounting portion 5200 operably supports atransmission arrangement generally designated as 5204 that is configuredto receive rotary output motions from the robotic system. The elongatedshaft assembly 5108 includes an outer closure tube 5110 that isrotatable and axially movable on a spine member 5120 that is rigidlycoupled to a tool mounting plate 5201 of the tool mounting portion 5200.The spine member 5120 also has a distal end 5122 that is coupled to theelongated channel portion 5020 of the surgical end effector 5012.

In use, it may be desirable to rotate the surgical end effector 5012about a longitudinal tool axis LT-LT defined by the elongated shaftassembly 5008. In various embodiments, the outer closure tube 5110 has aproximal end 5112 that is rotatably supported on the tool mounting plate5201 of the tool drive portion 5200 by a forward support cradle 5203.The proximal end 5112 of the outer closure tube 5110 is configured tooperably interface with a rotation transmission portion 5206 of thetransmission arrangement 5204. In various embodiments, the proximal end5112 of the outer closure tube 5110 is also supported on a closure sled5140 that is also movably supported on the tool mounting plate 5201. Aclosure tube gear segment 5114 is formed on the proximal end 5112 of theouter closure tube 5110 for meshing engagement with a rotation driveassembly 5150 of the rotation transmission 5206. As can be seen in FIG.105, the rotation drive assembly 5150, in at least one embodiment,comprises a rotation drive gear 5152 that is coupled to a correspondingfirst one of the driven discs or elements 1304 on the adapter side 1307of the tool mounting plate 5201 when the tool drive portion 5200 iscoupled to the tool holder 1270. The rotation drive assembly 5150further comprises a rotary driven gear 5154 that is rotatably supportedon the tool mounting plate 5201 in meshing engagement with the closuretube gear segment 5114 and the rotation drive gear 5152. Application ofa first rotary control motion from the robotic system 1000 through thetool holder 1270 and the adapter 1240 to the corresponding drivenelement 1304 will thereby cause rotation of the rotation drive gear5152. Rotation of the rotation drive gear 5152 ultimately results in therotation of the elongated shaft assembly 5108 (and the end effector5012) about the longitudinal tool axis LT-LT (represented by arrow “R”in FIG. 105).

Closure of the anvil 5070 relative to the surgical staple cartridge 5080is accomplished by axially moving the outer closure tube 5110 in thedistal direction “DD”. Such axial movement of the outer closure tube5110 may be accomplished by a closure transmission portion closuretransmission portion 5144 of the transmission arrangement 5204. Asindicated above, in various embodiments, the proximal end 5112 of theouter closure tube 5110 is supported by the closure sled 5140 whichenables the proximal end 5112 to rotate relative thereto, yet travelaxially with the closure sled 5140. In particular, as can be seen inFIG. 105, the closure sled 5140 has an upstanding tab 5141 that extendsinto a radial groove 5115 in the proximal end portion 5112 of the outerclosure tube 5110. In addition, as was described above, the closure sled5140 is slidably mounted to the tool mounting plate 5201. In variousembodiments, the closure sled 5140 has an upstanding portion 5142 thathas a closure rack gear 5143 formed thereon. The closure rack gear 5143is configured for driving engagement with the closure transmission 5144.

In various forms, the closure transmission 5144 includes a closure spurgear 5145 that is coupled to a corresponding second one of the drivendiscs or elements 1304 on the adapter side 1307 of the tool mountingplate 5201. Thus, application of a second rotary control motion from therobotic system 1000 through the tool holder 1270 and the adapter 1240 tothe corresponding second driven element 1304 will cause rotation of theclosure spur gear 5145 when the interface 1230 is coupled to the toolmounting portion 5200. The closure transmission 5144 further includes adriven closure gear set 5146 that is supported in meshing engagementwith the closure spur gear 5145 and the closure rack gear 5143. Thus,application of a second rotary control motion from the robotic system1000 through the tool holder 1270 and the adapter 1240 to thecorresponding second driven element 1304 will cause rotation of theclosure spur gear 5145 and ultimately drive the closure sled 5140 andthe outer closure tube 5110 axially. The axial direction in which theclosure tube 5110 moves ultimately depends upon the direction in whichthe second driven element 1304 is rotated. For example, in response toone rotary closure motion received from the robotic system 1000, theclosure sled 5140 will be driven in the distal direction “DD” andultimately the outer closure tube 5110 will be driven in the distaldirection as well. The outer closure tube 5110 has an opening 5117 inthe distal end 5116 that is configured for engagement with a tab 5071 onthe anvil 5070 in the manners described above. As the outer closure tube5110 is driven distally, the proximal end 5116 of the closure tube 5110will contact the anvil 5070 and pivot it closed. Upon application of an“opening” rotary motion from the robotic system 1000, the closure sled5140 and outer closure tube 5110 will be driven in the proximaldirection “PD” and pivot the anvil 5070 to the open position in themanners described above.

In at least one embodiment, the drive shaft 5130 has a proximal end 5137that has a proximal shaft gear 5138 attached thereto. The proximal shaftgear 5138 is supported in meshing engagement with a distal drive gear5162 attached to a rotary drive bar 5160 that is rotatably supportedwith spine member 5120. Rotation of the rotary drive bar 5160 andultimately rotary drive shaft 5130 is controlled by a rotary knifetransmission 5207 which comprises a portion of the transmissionarrangement 5204 supported on the tool mounting plate 5210. In variousembodiments, the rotary knife transmission 5207 comprises a rotary knifedrive system 5170 that is operably supported on the tool mounting plate5201. In various embodiments, the knife drive system 5170 includes arotary drive gear 5172 that is coupled to a corresponding third one ofthe driven discs or elements 1304 on the adapter side of the toolmounting plate 5201 when the tool drive portion 5200 is coupled to thetool holder 1270. The knife drive system 5170 further comprises a firstrotary driven gear 5174 that is rotatably supported on the tool mountingplate 5201 in meshing engagement with a second rotary driven gear 5176and the rotary drive gear 5172. The second rotary driven gear 5176 iscoupled to a proximal end portion 5164 of the rotary drive bar 5160.

Rotation of the rotary drive gear 5172 in a first rotary direction willresult in the rotation of the rotary drive bar 5160 and rotary driveshaft 5130 in a first direction. Conversely, rotation of the rotarydrive gear 5172 in a second rotary direction (opposite to the firstrotary direction) will cause the rotary drive bar 5160 and rotary driveshaft 5130 to rotate in a second direction. 2400. Thus, rotation of thedrive shaft 2440 results in rotation of the drive sleeve 2400.

One method of operating the surgical tool 5000 will now be described.The tool drive 5200 is operably coupled to the interface 1240 of therobotic system 1000. The controller 1001 of the robotic system 1000 isoperated to locate the tissue to be cut and stapled between the openanvil 5070 and the surgical staple cartridge 5080. Once the surgical endeffector 5012 has been positioned by the robot system 1000 such that thetarget tissue is located between the anvil 5070 and the surgical staplecartridge 5080, the controller 1001 of the robotic system 1000 may beactivated to apply the second rotary output motion to the second drivenelement 1304 coupled to the closure spur gear 5145 to drive the closuresled 5140 and the outer closure tube 5110 axially in the distaldirection to pivot the anvil 5070 closed in the manner described above.Once the robotic controller 1001 determines that the anvil 5070 has beenclosed by, for example, sensors in the surgical end effector 5012 and/orthe tool drive portion 5200, the robotic controller 1001 system mayprovide the surgeon with an indication that signifies the closure of theanvil. Such indication may be, for example, in the form of a lightand/or audible sound, tactile feedback on the control members, etc. Thenthe surgeon may initiate the firing process. In alternative embodiments,however, the robotic controller 1001 may automatically commence thefiring process.

To commence the firing process, the robotic controller applies a thirdrotary output motion to the third driven disc or element 1304 coupled tothe rotary drive gear 5172. Rotation of the rotary drive gear 5172results in the rotation of the rotary drive bar 5160 and rotary driveshaft 5130 in the manner described above. Firing and formation of thesurgical staples 5098 can be best understood from reference to FIGS.106, 108, and 109. As the sled assembly 5030 is driven in the distaldirection “DD” through the surgical staple cartridge 5080, the distalwedge segments 5060 first contact the staple pushers 5088 and start tomove them toward the closed anvil 5070. As the sled assembly 5030continues to move distally, the outboard drivers 5052 will drop into thecorresponding activation cavity 5026 in the channel pan 5022. Theopposite end of each outboard driver 5052 will then contact thecorresponding outboard pusher 5088 that has moved up the distal andintermediate wedge segments 5060, 5062. Further distal movement of thesled assembly 5030 causes the outboard drivers 5052 to rotate and drivethe corresponding pushers 5088 toward the anvil 5070 to cause thestaples 5098 supported thereon to be formed as they are driven into theanvil 5070. It will be understood that as the sled assembly 5030 movesdistally, the knife blade 5040 cuts through the tissue that is clampedbetween the anvil and the staple cartridge. Because the inboard drivers5054 and outboard drivers 5052 are attached to the same shaft 5056 andthe inboard drivers 5054 are radially offset from the outboard drivers5052 on the shaft 5056, as the outboard drivers 5052 are driving theircorresponding pushers 5088 toward the anvil 5070, the inboard drivers5054 drop into their next corresponding activation cavity 5028 to causethem to rotatably or reciprocatingly drive the corresponding inboardpushers 5088 towards the closed anvil 5070 in the same manner. Thus, thelaterally corresponding outboard staples 5098 on each side of thecentrally disposed slot 5084 are simultaneously formed together and thelaterally corresponding inboard staples 5098 on each side of the slot5084 are simultaneously formed together as the sled assembly 5030 isdriven distally. Once the robotic controller 1001 determines that thesled assembly 5030 has reached its distal most position—either throughsensors or through monitoring the amount of rotary input applied to thedrive shaft 5130 and/or the rotary drive bar 5160, the controller 1001may then apply a third rotary output motion to the drive shaft 5130 torotate the drive shaft 5130 in an opposite direction to retract the sledassembly 5030 back to its starting position. Once the sled assembly 5030has been retracted to the starting position (as signaled by sensors inthe end effector 5012 and/or the tool drive portion 5200), theapplication of the second rotary motion to the drive shaft 5130 isdiscontinued. Thereafter, the surgeon may manually activate the anvilopening process or it may be automatically commenced by the roboticcontroller 1001. To open the anvil 5070, the second rotary output motionis applied to the closure spur gear 5145 to drive the closure sled 5140and the outer closure tube 5110 axially in the proximal direction. Asthe closure tube 5110 moves proximally, the opening 5117 in the distalend 5116 of the closure tube 5110 contacts the tab 5071 on the anvil5070 to pivot the anvil 5070 to the open position. A spring may also beemployed to bias the anvil 5070 to the open position when the closuretube 5116 has been returned to the starting position. Again, sensors inthe surgical end effector 5012 and/or the tool mounting portion 5200 mayprovide the robotic controller 1001 with a signal indicating that theanvil 5070 is now open. Thereafter, the surgical end effector 5012 maybe withdrawn from the surgical site.

FIGS. 112-117 diagrammatically depict the sequential firing of staplesin a surgical tool assembly 5000′ that is substantially similar to thesurgical tool assembly 5000 described above. In this embodiment, theinboard and outboard drivers 5052′, 5054′ have a cam-like shape with acam surface 5053 and an actuator protrusion 5055 as shown in FIGS.112-118. The drivers 5052′, 5054′ are journaled on the same shaft 5056′that is rotatably supported by the sled assembly 5030′. In thisembodiment, the sled assembly 5030′ has distal wedge segments 5060′ forengaging the pushers 5088. FIG. 112 illustrates an initial position oftwo inboard or outboard drivers 5052′, 5054′ as the sled assembly 5030′is driven in the distal direction “DD”. As can be seen in that Figure,the pusher 5088 a has advanced up the wedge segment 5060′ and hascontacted the driver 5052′, 5054′. Further travel of the sled assembly5030′ in the distal direction causes the driver 5052′, 5054′ to pivot inthe “P” direction (FIG. 113) until the actuator portion 5055 contactsthe end wall 5029 a of the activation cavity 5026, 5028 as shown in FIG.114. Continued advancement of the sled assembly 5030′ in the distaldirection “DD” causes the driver 5052′, 5054′ to rotate in the “D”direction as shown in FIG. 115. As the driver 5052′, 5054′ rotates, thepusher 5088 a rides up the cam surface 5053 to the final verticalposition shown in FIG. 116. When the pusher 5088 a reaches the finalvertical position shown in FIGS. 116 and 117, the staple (not shown)supported thereon has been driven into the staple forming surface of theanvil to form the staple.

FIGS. 119-124 illustrate a surgical end effector 5312 that may beemployed for example, in connection with the tool mounting portion 1300and shaft 2008 described in detail above. In various forms, the surgicalend effector 5312 includes an elongated channel 5322 that is constructedas described above for supporting a surgical staple cartridge 5330therein. The surgical staple cartridge 5330 comprises a body portion5332 that includes a centrally disposed slot 5334 for accommodating anupstanding support portion 5386 of a sled assembly 5380. See FIGS.119-121. The surgical staple cartridge body portion 5332 furtherincludes a plurality of cavities 5336 for movably supportingstaple-supporting pushers 5350 therein. The cavities 5336 may bearranged in spaced longitudinally extending rows 5340, 5342, 5344, 5346.The rows 5340, 5342 are located on one lateral side of the longitudinalslot 5334 and the rows 5344, 5346 are located on the other side oflongitudinal slot 5334. In at least one embodiment, the pushers 5350 areconfigured to support two surgical staples 5352 thereon. In particular,each pusher 5350 located on one side of the elongated slot 5334 supportsone staple 5352 in row 5340 and one staple 5352 in row 5342 in astaggered orientation. Likewise, each pusher 5350 located on the otherside of the elongated slot 5334 supports one surgical staple 5352 in row5344 and another surgical staple 5352 in row 5346 in a staggeredorientation. Thus, every pusher 5350 supports two surgical staples 5352.

As can be further seen in FIGS. 119, 120, the surgical staple cartridge5330 includes a plurality of rotary drivers 5360. More particularly, therotary drivers 5360 on one side of the elongated slot 5334 are arrangedin a single line 5370 and correspond to the pushers 5350 in lines 5340,5342. In addition, the rotary drivers 5360 on the other side of theelongated slot 5334 are arranged in a single line 5372 and correspond tothe pushers 5350 in lines 5344, 5346. As can be seen in FIG. 119, eachrotary driver 5360 is rotatably supported within the staple cartridgebody 5332. More particularly, each rotary driver 5360 is rotatablyreceived on a corresponding driver shaft 5362. Each driver 5360 has anarcuate ramp portion 5364 formed thereon that is configured to engage anarcuate lower surface 5354 formed on each pusher 5350. See FIG. 124. Inaddition, each driver 5360 has a lower support portion 5366 extendtherefrom to slidably support the pusher 5360 on the channel 5322. Eachdriver 5360 has a downwardly extending actuation rod 5368 that isconfigured for engagement with a sled assembly 5380.

As can be seen in FIG. 121, in at least one embodiment, the sledassembly 5380 includes a base portion 5382 that has a foot portion 5384that is sized to be slidably received in a slot 5333 in the channel5322. See FIG. 119. The sled assembly 5380 includes an upstandingsupport portion 5386 that supports a tissue cutting blade or tissuecutting instrument 5388. The upstanding support portion 5386 terminatesin a top portion 5390 that has a pair of laterally extending retainingfins 5392 protruding therefrom. The fins 5392 are positioned to bereceived within corresponding slots (not shown) in the anvil (notshown). As with the above-described embodiments, the fins 5392 and thefoot portion 5384 serve to retain the anvil (not shown) in a desiredspaced closed position as the sled assembly 5380 is driven distallythrough the tissue clamped within the surgical end effector 5312. Theupstanding support portion 5386 is configured for attachment to a knifebar 2200 (FIG. 40). The sled assembly 5380 further has ahorizontally-extending actuator plate 5394 that is shaped for actuatingengagement with each of the actuation rods 5368 on the pushers 5360.

Operation of the surgical end effector 5312 will now be explained withreference to FIGS. 119 and 120. As the sled assembly 5380 is driven inthe distal direction “DD” through the staple cartridge 5330, theactuator plate 5394 sequentially contacts the actuation rods 5368 on thepushers 5360. As the sled assembly 5380 continues to move distally, theactuator plate 5394 sequentially contacts the actuator rods 5368 of thedrivers 5360 on each side of the elongated slot 5334. Such action causesthe drivers 5360 to rotate from a first unactuated position to anactuated portion wherein the pushers 5350 are driven towards the closedanvil. As the pushers 5350 are driven toward the anvil, the surgicalstaples 5352 thereon are driven into forming contact with the undersideof the anvil. Once the robotic system 1000 determines that the sledassembly 5080 has reached its distal most position through sensors orother means, the control system of the robotic system 1000 may thenretract the knife bar and sled assembly 5380 back to the startingposition. Thereafter, the robotic control system may then activate theprocedure for returning the anvil to the open position to release thestapled tissue.

FIGS. 125-129 depict one form of an automated reloading systemembodiment of the present invention, generally designated as 5500. Inone form, the automated reloading system 5500 is configured to replace a“spent” surgical end effector component in a manipulatable surgical toolportion of a robotic surgical system with a “new” surgical end effectorcomponent. As used herein, the term “surgical end effector component”may comprise, for example, a surgical staple cartridge, a disposableloading unit or other end effector components that, when used, are spentand must be replaced with a new component. Furthermore, the term “spent”means that the end effector component has been activated and is nolonger useable for its intended purpose in its present state. Forexample, in the context of a surgical staple cartridge or disposableloading unit, the term “spent” means that at least some of the unformedstaples that were previously supported therein have been “fired”therefrom. As used herein, the term “new” surgical end effectorcomponent refers to an end effector component that is in condition forits intended use. In the context of a surgical staple cartridge ordisposable loading unit, for example, the term “new” refers to such acomponent that has unformed staples therein and which is otherwise readyfor use.

In various embodiments, the automated reloading system 5500 includes abase portion 5502 that may be strategically located within a workenvelope 1109 of a robotic arm cart 1100 (FIG. 26) of a robotic system1000. As used herein, the term “manipulatable surgical tool portion”collectively refers to a surgical tool of the various types disclosedherein and other forms of surgical robotically-actuated tools that areoperably attached to, for example, a robotic arm cart 1100 or similardevice that is configured to automatically manipulate and actuate thesurgical tool. The term “work envelope” as used herein refers to therange of movement of the manipulatable surgical tool portion of therobotic system. FIG. 26 generally depicts an area that may comprise awork envelope of the robotic arm cart 1100. Those of ordinary skill inthe art will understand that the shape and size of the work envelopedepicted therein is merely illustrative. The ultimate size, shape andlocation of a work envelope will ultimately depend upon theconstruction, range of travel limitations, and location of themanipulatable surgical tool portion. Thus, the term “work envelope” asused herein is intended to cover a variety of different sizes and shapesof work envelopes and should not be limited to the specific size andshape of the sample work envelope depicted in FIG. 26.

As can be seen in FIG. 125, the base portion 5502 includes a newcomponent support section or arrangement 5510 that is configured tooperably support at least one new surgical end effector component in a“loading orientation”. As used herein, the term “loading orientation”means that the new end effector component is supported in such away soas to permit the corresponding component support portion of themanipulatable surgical tool portion to be brought into loadingengagement with (i.e., operably seated or operably attached to) the newend effector component (or the new end effector component to be broughtinto loading engagement with the corresponding component support portionof the manipulatable surgical tool portion) without human interventionbeyond that which may be necessary to actuate the robotic system. Aswill be further appreciated as the present Detailed Descriptionproceeds, in at least one embodiment, the preparation nurse will loadthe new component support section before the surgery with theappropriate length and color cartridges (some surgical staple cartridgesmay support certain sizes of staples the size of which may be indicatedby the color of the cartridge body) required for completing the surgicalprocedure. However, no direct human interaction is necessary during thesurgery to reload the robotic endocutter. In one form, the surgical endeffector component comprises a staple cartridge 2034 that is configuredto be operably seated within a component support portion (elongatedchannel) of any of the various other end effector arrangements describedabove. For explanation purposes, new (unused) cartridges will bedesignated as “2034 a” and spent cartridges will be designated as “2034b”. The Figures depict cartridges 2034 a, 2034 b designed for use with asurgical end effector 2012 that includes a channel 2022 and an anvil2024, the construction and operation of which were discussed in detailabove. Cartridges 2034 a, 2034 b are identical to cartridges 2034described above. In various embodiments, the cartridges 2034 a, 2034 bare configured to be snappingly retained (i.e., loading engagement)within the channel 2022 of a surgical end effector 2012. As the presentDetailed Description proceeds, however, those of ordinary skill in theart will appreciate that the unique and novel features of the automatedcartridge reloading system 5500 may be effectively employed inconnection with the automated removal and installation of othercartridge arrangements without departing from the spirit and scope ofthe present invention.

In the depicted embodiment, the term “loading orientation” means thatthe distal tip portion 2035 a of the a new surgical staple cartridge2034 a is inserted into a corresponding support cavity 5512 in the newcartridge support section 5510 such that the proximal end portion 2037 aof the new surgical staple cartridge 2034 a is located in a convenientorientation for enabling the arm cart 1100 to manipulate the surgicalend effector 2012 into a position wherein the new cartridge 2034 a maybe automatically loaded into the channel 2022 of the surgical endeffector 2012. In various embodiments, the base 5502 includes at leastone sensor 5504 which communicates with the control system 1003 of therobotic controller 1001 to provide the control system 1003 with thelocation of the base 5502 and/or the reload length and color doe eachstaged or new cartridge 2034 a.

As can also be seen in the Figures, the base 5502 further includes acollection receptacle 5520 that is configured to collect spentcartridges 2034 b that have been removed or disengaged from the surgicalend effector 2012 that is operably attached to the robotic system 1000.In addition, in one form, the automated reloading system 5500 includesan extraction system 5530 for automatically removing the spent endeffector component from the corresponding support portion of the endeffector or manipulatable surgical tool portion without specific humanintervention beyond that which may be necessary to activate the roboticsystem. In various embodiments, the extraction system 5530 includes anextraction hook member 5532. In one form, for example, the extractionhook member 5532 is rigidly supported on the base portion 5502. In oneembodiment, the extraction hook member has at least one hook 5534 formedthereon that is configured to hookingly engage the distal end 2035 of aspent cartridge 2034 b when it is supported in the elongated channel2022 of the surgical end effector 2012. In various forms, the extractionhook member 5532 is conveniently located within a portion of thecollection receptacle 5520 such that when the spent end effectorcomponent (cartridge 2034 b) is brought into extractive engagement withthe extraction hook member 5532, the spent end effector component(cartridge 2034 b) is dislodged from the corresponding component supportportion (elongated channel 2022), and falls into the collectionreceptacle 5020. Thus, to use this embodiment, the manipulatablesurgical tool portion manipulates the end effector attached thereto tobring the distal end 2035 of the spent cartridge 2034 b therein intohooking engagement with the hook 5534 and then moves the end effector insuch a way to dislodge the spent cartridge 2034 b from the elongatedchannel 2022.

In other arrangements, the extraction hook member 5532 comprises arotatable wheel configuration that has a pair of diametrically-opposedhooks 5334 protruding therefrom. See FIGS. 125 and 128. The extractionhook member 5532 is rotatably supported within the collection receptacle5520 and is coupled to an extraction motor 5540 that is controlled bythe controller 1001 of the robotic system. This form of the automatedreloading system 5500 may be used as follows. FIG. 127 illustrates theintroduction of the surgical end effector 2012 that is operably attachedto the manipulatable surgical tool portion 1200. As can be seen in thatFigure, the arm cart 1100 of the robotic system 1000 locates thesurgical end effector 2012 in the shown position wherein the hook end5534 of the extraction member 5532 hookingly engages the distal end 2035of the spent cartridge 2034 b in the surgical end effector 2012. Theanvil 2024 of the surgical end effector 2012 is in the open position.After the distal end 2035 of the spent cartridge 2034 b is engaged withthe hook end 5532, the extraction motor 5540 is actuated to rotate theextraction wheel 5532 to disengage the spent cartridge 2034 b from thechannel 2022. To assist with the disengagement of the spent cartridge2034 b from the channel 2022 (or if the extraction member 5530 isstationary), the robotic system 1000 may move the surgical end effector2012 in an upward direction (arrow “U” in FIG. 128). As the spentcartridge 2034 b is dislodged from the channel 2022, the spent cartridge2034 b falls into the collection receptacle 5520. Once the spentcartridge 2034 b has been removed from the surgical end effector 2012,the robotic system 1000 moves the surgical end effector 2012 to theposition shown in FIG. 126.

In various embodiments, a sensor arrangement 5533 is located adjacent tothe extraction member 5532 that is in communication with the controller1001 of the robotic system 1000. The sensor arrangement 5533 maycomprise a sensor that is configured to sense the presence of thesurgical end effector 2012 and, more particularly the tip 2035 b of thespent surgical staple cartridge 2034 b thereof as the distal tip portion2035 b is brought into engagement with the extraction member 5532. Insome embodiments, the sensor arrangement 5533 may comprise, for example,a light curtain arrangement. However, other forms of proximity sensorsmay be employed. In such arrangement, when the surgical end effector2012 with the spent surgical staple cartridge 2034 b is brought intoextractive engagement with the extraction member 5532, the sensor sensesthe distal tip 2035 b of the surgical staple cartridge 2034 b (e.g., thelight curtain is broken). When the extraction member 5532 spins and popsthe surgical staple cartridge 2034 b loose and it falls into thecollection receptacle 5520, the light curtain is again unbroken. Becausethe surgical end effector 2012 was not moved during this procedure, therobotic controller 1001 is assured that the spent surgical staplecartridge 2034 b has been removed therefrom. Other sensor arrangementsmay also be successfully employed to provide the robotic controller 1001with an indication that the spent surgical staple cartridge 2034 b hasbeen removed from the surgical end effector 2012.

As can be seen in FIG. 129, the surgical end effector 2012 is positionedto grasp a new surgical staple cartridge 2034 a between the channel 2022and the anvil 2024. More specifically, as shown in FIGS. 126 and 129,each cavity 5512 has a corresponding upstanding pressure pad 5514associated with it. The surgical end effector 2012 is located such thatthe pressure pad 5514 is located between the new cartridge 2034 a andthe anvil 2024. Once in that position, the robotic system 1000 closesthe anvil 2024 onto the pressure pad 5514 which serves to push the newcartridge 2034 a into snapping engagement with the channel 2022 of thesurgical end effector 2012. Once the new cartridge 2034 a has beensnapped into position within the elongated channel 2022, the roboticsystem 1000 then withdraws the surgical end effector 2012 from theautomated cartridge reloading system 5500 for use in connection withperforming another surgical procedure.

FIGS. 130-134 depict another automated reloading system 5600 that may beused to remove a spent disposable loading unit 3612 from a manipulatablesurgical tool arrangement 3600 (FIGS. 77-90) that is operably attachedto an arm cart 1100 or other portion of a robotic system 1000 and reloada new disposable loading unit 3612 therein. As can be seen in FIGS. 130and 131, one form of the automated reloading system 5600 includes ahousing 5610 that has a movable support assembly in the form of a rotarycarrousel top plate 5620 supported thereon which cooperates with thehousing 5610 to form a hollow enclosed area 5612. The automatedreloading system 5600 is configured to be operably supported within thework envelop of the manipulatable surgical tool portion of a roboticsystem as was described above. In various embodiments, the rotarycarrousel plate 5620 has a plurality of holes 5622 for supporting aplurality of orientation tubes 5660 therein. As can be seen in FIGS. 131and 132, the rotary carrousel plate 5620 is affixed to a spindle shaft5624. The spindle shaft 5624 is centrally disposed within the enclosedarea 5612 and has a spindle gear 5626 attached thereto. The spindle gear5626 is in meshing engagement with a carrousel drive gear 5628 that iscoupled to a carrousel drive motor 5630 that is in operativecommunication with the robotic controller 1001 of the robotic system1000.

Various embodiments of the automated reloading system 5600 may alsoinclude a carrousel locking assembly, generally designated as 5640. Invarious forms, the carrousel locking assembly 5640 includes a cam disc5642 that is affixed to the spindle shaft 5624. The spindle gear 5626may be attached to the underside of the cam disc 5642 and the cam disc5642 may be keyed onto the spindle shaft 5624. In alternativearrangements, the spindle gear 5626 and the cam disc 5642 may beindependently non-rotatably affixed to the spindle shaft 5624. As can beseen in FIGS. 131 and 132, a plurality of notches 5644 are spaced aroundthe perimeter of the cam disc 5642. A locking arm 5648 is pivotallymounted within the housing 5610 and is biased into engagement with theperimeter of the cam disc 5642 by a locking spring 5649. As can be seenin FIG. 130, the outer perimeter of the cam disc 5642 is rounded tofacilitate rotation of the cam disc 5642 relative to the locking arm5648. The edges of each notch 5644 are also rounded such that when thecam disc 5642 is rotated, the locking arm 5648 is cammed out ofengagement with the notches 5644 by the perimeter of the cam disc 5642.

Various forms of the automated reloading system 5600 are configured tosupport a portable/replaceable tray assembly 5650 that is configured tosupport a plurality of disposable loading units 3612 in individualorientation tubes 5660. More specifically and with reference to FIGS.131 and 132, the replaceable tray assembly 5650 comprises a tray 5652that has a centrally-disposed locator spindle 5654 protruding from theunderside thereof. The locator spindle 5654 is sized to be receivedwithin a hollow end 5625 of spindle shaft 5624. The tray 5652 has aplurality of holes 5656 therein that are configured to support anorientation tube 5660 therein. Each orientation tube 5660 is orientedwithin a corresponding hole 5656 in the replaceable tray assembly 5650in a desired orientation by a locating fin 5666 on the orientation tube5660 that is designed to be received within a corresponding locatingslot 5658 in the tray assembly 5650. In at least one embodiment, thelocating fin 5666 has a substantially V-shaped cross-sectional shapethat is sized to fit within a V-shaped locating slot 5658. Sucharrangement serves to orient the orientation tube 5660 in a desiredstarting position while enabling it to rotate within the hole 5656 whena rotary motion is applied thereto. That is, when a rotary motion isapplied to the orientation tube 5660 the V-shaped locating fin 5666 willpop out of its corresponding locating slot enabling the tube 5660 torotate relative to the tray 5652 as will be discussed in further detailbelow. As can also be seen in FIGS. 130-132, the replaceable tray 5652may be provided with one or more handle portions 5653 to facilitatetransport of the tray assembly 5652 when loaded with orientation tubes5660.

As can be seen in FIG. 134, each orientation tube 5660 comprises a bodyportion 5662 that has a flanged open end 5664. The body portion 5662defines a cavity 5668 that is sized to receive a portion of a disposableloading unit 3612 therein. To properly orient the disposable loadingunit 3612 within the orientation tube 5660, the cavity 5668 has a flatlocating surface 5670 formed therein. As can be seen in FIG. 134, theflat locating surface 5670 is configured to facilitate the insertion ofthe disposable loading unit into the cavity 5668 in a desired orpredetermined non-rotatable orientation. In addition, the end 5669 ofthe cavity 5668 may include a foam or cushion material 5672 that isdesigned to cushion the distal end of the disposable loading unit 3612within the cavity 5668. Also, the length of the locating surface maycooperate with a sliding support member 3689 of the axial drive assembly3680 of the disposable loading unit3612 to further locate the disposableloading unit 3612 at a desired position within the orientation tube5660.

The orientation tubes 5660 may be fabricated from Nylon, polycarbonate,polyethylene, liquid crystal polymer, 6061 or 7075 aluminum, titanium,300 or 400 series stainless steel, coated or painted steel, platedsteel, etc. and, when loaded in the replaceable tray 5662 and thelocator spindle 5654 is inserted into the hollow end 5625 of spindleshaft 5624, the orientation tubes 5660 extend through correspondingholes 5662 in the carrousel top plate 5620. Each replaceable tray 5662is equipped with a location sensor 5663 that communicates with thecontrol system 1003 of the controller 1001 of the robotic system 1000.The sensor 5663 serves to identify the location of the reload system,and the number, length, color and fired status of each reload housed inthe tray. In addition, an optical sensor or sensors 5665 thatcommunicate with the robotic controller 1001 may be employed to sensethe type/size/length of disposable loading units that are loaded withinthe tray 5662.

Various embodiments of the automated reloading system 5600 furtherinclude a drive assembly 5680 for applying a rotary motion to theorientation tube 5660 holding the disposable loading unit 3612 to beattached to the shaft 3700 of the surgical tool 3600 (collectively the“manipulatable surgical tool portion”) that is operably coupled to therobotic system. The drive assembly 5680 includes a support yoke 5682that is attached to the locking arm 5648. Thus, the support yoke 5682pivots with the locking arm 5648. The support yoke 5682 rotatablysupports a tube idler wheel 5684 and a tube drive wheel 5686 that isdriven by a tube motor 5688 attached thereto. Tube motor 5688communicates with the control system 1003 and is controlled thereby. Thetube idler wheel 5684 and tube drive wheel 5686 are fabricated from, forexample, natural rubber, sanoprene, isoplast, etc. such that the outersurfaces thereof create sufficient amount of friction to result in therotation of an orientation tube 5660 in contact therewith uponactivation of the tube motor 5688. The idler wheel 5684 and tube drivewheel 5686 are oriented relative to each other to create a cradle area5687 therebetween for receiving an orientation tube 5060 in drivingengagement therein.

In use, one or more of the orientation tubes 5660 loaded in theautomated reloading system 5600 are left empty, while the otherorientation tubes 5660 may operably support a corresponding newdisposable loading unit 3612 therein. As will be discussed in furtherdetail below, the empty orientation tubes 5660 are employed to receive aspent disposable loading unit 3612 therein.

The automated reloading system 5600 may be employed as follows after thesystem 5600 is located within the work envelope of the manipulatablesurgical tool portion of a robotic system. If the manipulatable surgicaltool portion has a spent disposable loading unit 3612 operably coupledthereto, one of the orientation tubes 5660 that are supported on thereplaceable tray 5662 is left empty to receive the spent disposableloading unit 3612 therein. If, however, the manipulatable surgical toolportion does not have a disposable loading unit 3612 operably coupledthereto, each of the orientation tubes 5660 may be provided with aproperly oriented new disposable loading unit 3612.

As described hereinabove, the disposable loading unit 3612 employs arotary “bayonet-type” coupling arrangement for operably coupling thedisposable loading unit 3612 to a corresponding portion of themanipulatable surgical tool portion. That is, to attach a disposableloading unit 3612 to the corresponding portion of the manipulatablesurgical tool portion (3700—see FIG. 83, 84), a rotary installationmotion must be applied to the disposable loading unit 3612 and/or thecorresponding portion of the manipulatable surgical tool portion whenthose components have been moved into loading engagement with eachother. Such installation motions are collectively referred to herein as“loading motions”. Likewise, to decouple a spent disposable loading unit3612 from the corresponding portion of the manipulatable surgical tool,a rotary decoupling motion must be applied to the spent disposableloading unit 3612 and/or the corresponding portion of the manipulatablesurgical tool portion while simultaneously moving the spent disposableloading unit and the corresponding portion of the manipulatable surgicaltool away from each other. Such decoupling motions are collectivelyreferred to herein as “extraction motions”.

To commence the loading process, the robotic system 1000 is activated tomanipulate the manipulatable surgical tool portion and/or the automatedreloading system 5600 to bring the manipulatable surgical tool portioninto loading engagement with the new disposable loading unit 3612 thatis supported in the orientation tube 5660 that is in driving engagementwith the drive assembly 5680. Once the robotic controller 1001 (FIG. 25)of the robotic control system 1000 has located the manipulatablesurgical tool portion in loading engagement with the new disposableloading unit 3612, the robotic controller 1001 activates the driveassembly 5680 to apply a rotary loading motion to the orientation tube5660 in which the new disposable loading unit 3612 is supported and/orapplies another rotary loading motion to the corresponding portion ofthe manipulatable surgical tool portion. Upon application of such rotaryloading motions(s), the robotic controller 1001 also causes thecorresponding portion of the manipulatable surgical tool portion to bemoved towards the new disposable loading unit 3612 into loadingengagement therewith. Once the disposable loading unit 3612 is inloading engagement with the corresponding portion of the manipulatabletool portion, the loading motions are discontinued and the manipulatablesurgical tool portion may be moved away from the automated reloadingsystem 5600 carrying with it the new disposable loading unit 3612 thathas been operably coupled thereto.

To decouple a spent disposable loading unit 3612 from a correspondingmanipulatable surgical tool portion, the robotic controller 1001 of therobotic system manipulates the manipulatable surgical tool portion so asto insert the distal end of the spent disposable loading unit 3612 intothe empty orientation tube 5660 that remains in driving engagement withthe drive assembly 5680. Thereafter, the robotic controller 1001activates the drive assembly 5680 to apply a rotary extraction motion tothe orientation tube 5660 in which the spent disposable loading unit3612 is supported and/or applies a rotary extraction motion to thecorresponding portion of the manipulatable surgical tool portion. Therobotic controller 1001 also causes the manipulatable surgical toolportion to withdraw away from the spent rotary disposable loading unit3612. Thereafter the rotary extraction motion(s) are discontinued.

After the spent disposable loading unit 3612 has been removed from themanipulatable surgical tool portion, the robotic controller 1001 mayactivate the carrousel drive motor 5630 to index the carrousel top plate5620 to bring another orientation tube 5660 that supports a newdisposable loading unit 3612 therein into driving engagement with thedrive assembly 5680. Thereafter, the loading process may be repeated toattach the new disposable loading unit 3612 therein to the portion ofthe manipulatable surgical tool portion. The robotic controller 1001 mayrecord the number of disposable loading units that have been used from aparticular replaceable tray 5652. Once the controller 1001 determinesthat all of the new disposable loading units 3612 have been used fromthat tray, the controller 1001 may provide the surgeon with a signal(visual and/or audible) indicating that the tray 5652 supporting all ofthe spent disposable loading units 3612 must be replaced with a new tray5652 containing new disposable loading units 3612.

FIGS. 135-140 depict another non-limiting embodiment of a surgical tool6000 of the present invention that is well-adapted for use with arobotic system 1000 that has a tool drive assembly 1010 (FIG. 27) thatis operatively coupled to a master controller 1001 that is operable byinputs from an operator (i.e., a surgeon). As can be seen in FIG. 135,the surgical tool 6000 includes a surgical end effector 6012 thatcomprises an endocutter. In at least one form, the surgical tool 6000generally includes an elongated shaft assembly 6008 that has a proximalclosure tube 6040 and a distal closure tube 6042 that are coupledtogether by an articulation joint 6100. The surgical tool 6000 isoperably coupled to the manipulator by a tool mounting portion,generally designated as 6200. The surgical tool 6000 further includes aninterface 6030 which may mechanically and electrically couple the toolmounting portion 6200 to the manipulator in the various mannersdescribed in detail above.

In at least one embodiment, the surgical tool 6000 includes a surgicalend effector 6012 that comprises, among other things, at least onecomponent 6024 that is selectively movable between first and secondpositions relative to at least one other component 6022 in response tovarious control motions applied to component 6024 as will be discussedin further detail below to perform a surgical procedure. In variousembodiments, component 6022 comprises an elongated channel 6022configured to operably support a surgical staple cartridge 6034 thereinand component 6024 comprises a pivotally translatable clamping member,such as an anvil 6024. Various embodiments of the surgical end effector6012 are configured to maintain the anvil 6024 and elongated channel6022 at a spacing that assures effective stapling and severing of tissueclamped in the surgical end effector 6012. Unless otherwise stated, theend effector 6012 is similar to the surgical end effector 2012 describedabove and includes a cutting instrument (not shown) and a sled (notshown). The anvil 6024 may include a tab 6027 at its proximal end thatinteracts with a component of the mechanical closure system (describedfurther below) to facilitate the opening of the anvil 6024. Theelongated channel 6022 and the anvil 6024 may be made of an electricallyconductive material (such as metal) so that they may serve as part of anantenna that communicates with sensor(s) in the end effector, asdescribed above. The surgical staple cartridge 6034 could be made of anonconductive material (such as plastic) and the sensor may be connectedto or disposed in the surgical staple cartridge 6034, as was alsodescribed above.

As can be seen in FIG. 135, the surgical end effector 6012 is attachedto the tool mounting portion 6200 by the elongated shaft assembly 6008according to various embodiments. As shown in the illustratedembodiment, the elongated shaft assembly 6008 includes an articulationjoint generally designated as 6100 that enables the surgical endeffector 6012 to be selectively articulated about a first toolarticulation axis AA1-AA1 that is substantially transverse to alongitudinal tool axis LT-LT and a second tool articulation axis AA2-AA2that is substantially transverse to the longitudinal tool axis LT-LT aswell as the first articulation axis AA1-AA1. See FIG. 136. In variousembodiments, the elongated shaft assembly 6008 includes a closure tubeassembly 6009 that comprises a proximal closure tube 6040 and a distalclosure tube 6042 that are pivotably linked by a pivot links 6044 and6046. The closure tube assembly 6009 is movably supported on a spineassembly generally designated as 6102.

As can be seen in FIG. 137, the proximal closure tube 6040 is pivotallylinked to an intermediate closure tube joint 6043 by an upper pivot link6044U and a lower pivot link 6044L such that the intermediate closuretube joint 6043 is pivotable relative to the proximal closure tube 6040about a first closure axis CA1-CA1 and a second closure axis CA2-CA2. Invarious embodiments, the first closure axis CA1-CA1 is substantiallyparallel to the second closure axis CA2-CA2 and both closure axesCA1-CA1, CA2-CA2 are substantially transverse to the longitudinal toolaxis LT-LT. As can be further seen in FIG. 134, the intermediate closuretube joint 6043 is pivotally linked to the distal closure tube 6042 by aleft pivot link 6046L and a right pivot link 6046R such that theintermediate closure tube joint 6043 is pivotable relative to the distalclosure tube 6042 about a third closure axis CA3-CA3 and a fourthclosure axis CA4-CA4. In various embodiments, the third closure axisCA3-CA3 is substantially parallel to the fourth closure axis CA4-CA4 andboth closure axes CA3-CA3, CA4-CA4 are substantially transverse to thefirst and second closure axes CA1-CA1, CA2-CA2 as well as tolongitudinal tool axis LT-LT.

The closure tube assembly 6009 is configured to axially slide on thespine assembly 6102 in response to actuation motions applied thereto.The distal closure tube 6042 includes an opening 6045 which interfaceswith the tab 6027 on the anvil 6024 to facilitate opening of the anvil6024 as the distal closure tube 6042 is moved axially in the proximaldirection “PD”. The closure tubes 6040, 6042 may be made of electricallyconductive material (such as metal) so that they may serve as part ofthe antenna, as described above. Components of the spine assembly 6102may be made of a nonconductive material (such as plastic).

As indicated above, the surgical tool 6000 includes a tool mountingportion 6200 that is configured for operable attachment to the toolmounting assembly 1010 of the robotic system 1000 in the various mannersdescribed in detail above. As can be seen in FIG. 139, the tool mountingportion 6200 comprises a tool mounting plate 6202 that operably supportsa transmission arrangement 6204 thereon. In various embodiments, thetransmission arrangement 6204 includes an articulation transmission 6142that comprises a portion of an articulation system 6140 for articulatingthe surgical end effector 6012 about a first tool articulation axisTA1-TA1 and a second tool articulation axis TA2-TA2. The first toolarticulation axis TA1-TA1 is substantially transverse to the second toolarticulation axis TA2-TA2 and both of the first and second toolarticulation axes are substantially transverse to the longitudinal toolaxis LT-LT. See FIG. 136.

To facilitate selective articulation of the surgical end effector 6012about the first and second tool articulation axes TA1-TA1, TA2-TA2, thespine assembly 6102 comprises a proximal spine portion 6110 that ispivotally coupled to a distal spine portion 6120 by pivot pins 6122 forselective pivotal travel about TA1-TA1. Similarly, the distal spineportion 6120 is pivotally attached to the elongated channel 6022 of thesurgical end effector 6012 by pivot pins 6124 to enable the surgical endeffector 6012 to selectively pivot about the second tool axis TA2-TA2relative to the distal spine portion 6120.

In various embodiments, the articulation system 6140 further includes aplurality of articulation elements that operably interface with thesurgical end effector 6012 and an articulation control arrangement 6160that is operably supported in the tool mounting member 6200 as willdescribed in further detail below. In at least one embodiment, thearticulation elements comprise a first pair of first articulation cables6144 and 6146. The first articulation cables are located on a first orright side of the longitudinal tool axis. Thus, the first articulationcables are referred to herein as a right upper cable 6144 and a rightlower cable 6146. The right upper cable 6144 and the right lower cable6146 extend through corresponding passages 6147, 6148, respectivelyalong the right side of the proximal spine portion 6110. See FIG. 140.The articulation system 6140 further includes a second pair of secondarticulation cables 6150, 6152. The second articulation cables arelocated on a second or left side of the longitudinal tool axis. Thus,the second articulation cables are referred to herein as a left upperarticulation cable 6150 and a left articulation cable 6152. The leftupper articulation cable 6150 and the left lower articulation cable 6152extend through passages 6153, 6154, respectively in the proximal spineportion 6110.

As can be seen in FIG. 136, the right upper cable 6144 extends around anupper pivot joint 6123 and is attached to a left upper side of theelongated channel 6022 at a left pivot joint 6125. The right lower cable6146 extends around a lower pivot joint 6126 and is attached to a leftlower side of the elongated channel 6022 at left pivot joint 6125. Theleft upper cable 6150 extends around the upper pivot joint 6123 and isattached to a right upper side of the elongated channel 6022 at a rightpivot joint 6127. The left lower cable 6152 extends around the lowerpivot joint 6126 and is attached to a right lower side of the elongatedchannel 6022 at right pivot joint 6127. Thus, to pivot the surgical endeffector 6012 about the first tool articulation axis TA1-TA1 to the left(arrow “L”), the right upper cable 6144 and the right lower cable 6146must be pulled in the proximal direction “PD”. To articulate thesurgical end effector 6012 to the right (arrow “R”) about the first toolarticulation axis TA1-TA1, the left upper cable 6150 and the left lowercable 6152 must be pulled in the proximal direction “PD”. To articulatethe surgical end effector 6012 about the second tool articulation axisTA2-TA2, in an upward direction (arrow “U”), the right upper cable 6144and the left upper cable 6150 must be pulled in the proximal direction“PD”. To articulate the surgical end effector 6012 in the downwarddirection (arrow “DW”) about the second tool articulation axis TA2-TA2,the right lower cable 6146 and the left lower cable 6152 must be pulledin the proximal direction “PD”.

The proximal ends of the articulation cables 6144, 6146, 6150, 6152 arecoupled to the articulation control arrangement 6160 which comprises aball joint assembly that is a part of the articulation transmission6142. More specifically and with reference to FIG. 140, the ball jointassembly 6160 includes a ball-shaped member 6162 that is formed on aproximal portion of the proximal spine 6110. Movably supported on theball-shaped member 6162 is an articulation control ring 6164. As can befurther seen in FIG. 140, the proximal ends of the articulation cables6144, 6146, 6150, 6152 are coupled to the articulation control ring 6164by corresponding ball joint arrangements 6166. The articulation controlring 6164 is controlled by an articulation drive assembly 6170. As canbe most particularly seen in FIG. 140, the proximal ends of the firstarticulation cables 6144, 6146 are attached to the articulation controlring 6164 at corresponding spaced first points 6149, 6151 that arelocated on plane 6159. Likewise, the proximal ends of the secondarticulation cables 6150, 6152 are attached to the articulation controlring 6164 at corresponding spaced second points 6153, 6155 that are alsolocated along plane 6159. As the present Detailed Description proceeds,those of ordinary skill in the art will appreciate that such cableattachment configuration on the articulation control ring 6164facilitates the desired range of articulation motions as thearticulation control ring 6164 is manipulated by the articulation driveassembly 6170.

In various forms, the articulation drive assembly 6170 comprises ahorizontal articulation assembly generally designated as 6171. In atleast one form, the horizontal articulation assembly 6171 comprises ahorizontal push cable 6172 that is attached to a horizontal geararrangement 6180. The articulation drive assembly 6170 further comprisesa vertically articulation assembly generally designated as 6173. In atleast one form, the vertical articulation assembly 6173 comprises avertical push cable 6174 that is attached to a vertical gear arrangement6190. As can be seen in FIGS. 139 and 140, the horizontal push cable6172 extends through a support plate 6167 that is attached to theproximal spine portion 6110. The distal end of the horizontal push cable6174 is attached to the articulation control ring 6164 by acorresponding ball/pivot joint 6168. The vertical push cable 6174extends through the support plate 6167 and the distal end thereof isattached to the articulation control ring 6164 by a correspondingball/pivot joint 6169.

The horizontal gear arrangement 6180 includes a horizontal driven gear6182 that is pivotally mounted on a horizontal shaft 6181 that isattached to a proximal portion of the proximal spine portion 6110. Theproximal end of the horizontal push cable 6172 is pivotally attached tothe horizontal driven gear 6182 such that, as the horizontal driven gear6172 is rotated about horizontal pivot axis HA, the horizontal pushcable 6172 applies a first pivot motion to the articulation control ring6164. Likewise, the vertical gear arrangement 6190 includes a verticaldriven gear 6192 that is pivotally supported on a vertical shaft 6191attached to the proximal portion of the proximal spine portion 6110 forpivotal travel about a vertical pivot axis VA. The proximal end of thevertical push cable 6174 is pivotally attached to the vertical drivengear 6192 such that as the vertical driven gear 6192 is rotated aboutvertical pivot axis VA, the vertical push cable 6174 applies a secondpivot motion to the articulation control ring 6164.

The horizontal driven gear 6182 and the vertical driven gear 6192 aredriven by an articulation gear train 6300 that operably interfaces withan articulation shifter assembly 6320. In at least one form, thearticulation shifter assembly comprises an articulation drive gear 6322that is coupled to a corresponding one of the driven discs or elements1304 on the adapter side 1307 of the tool mounting plate 6202. See FIG.34. Thus, application of a rotary input motion from the robotic system1000 through the tool drive assembly 1010 to the corresponding drivenelement 1304 will cause rotation of the articulation drive gear 6322when the interface 1230 is coupled to the tool holder 1270. Anarticulation driven gear 6324 is attached to a splined shifter shaft6330 that is rotatably supported on the tool mounting plate 6202. Thearticulation driven gear 6324 is in meshing engagement with thearticulation drive gear 6322 as shown. Thus, rotation of thearticulation drive gear 6322 will result in the rotation of the shaft6330. In various forms, a shifter driven gear assembly 6340 is movablysupported on the splined portion 6332 of the shifter shaft 6330.

In various embodiments, the shifter driven gear assembly 6340 includes adriven shifter gear 6342 that is attached to a shifter plate 6344. Theshifter plate 6344 operably interfaces with a shifter solenoid assembly6350. The shifter solenoid assembly 6350 is coupled to correspondingpins 6352 by conductors 6352. See FIG. 139. Pins 6352 are oriented toelectrically communicate with slots 1258 (FIG. 33) on the tool side 1244of the adaptor 1240. Such arrangement serves to electrically couple theshifter solenoid assembly 6350 to the robotic controller 1001. Thus,activation of the shifter solenoid 6350 will shift the shifter drivengear assembly 6340 on the splined portion 6332 of the shifter shaft 6330as represented by arrow “S” in FIGS. 139 and 140. Various embodiments ofthe articulation gear train 6300 further include a horizontal gearassembly 6360 that includes a first horizontal drive gear 6362 that ismounted on a shaft 6361 that is rotatably attached to the tool mountingplate 6202. The first horizontal drive gear 6362 is supported in meshingengagement with a second horizontal drive gear 6364. As can be seen inFIG. 140, the horizontal driven gear 6182 is in meshing engagement withthe distal face portion 6365 of the second horizontal driven gear 6364.

Various embodiments of the articulation gear train 6300 further includea vertical gear assembly 6370 that includes a first vertical drive gear6372 that is mounted on a shaft 6371 that is rotatably supported on thetool mounting plate 6202. The first vertical drive gear 6372 issupported in meshing engagement with a second vertical drive gear 6374that is concentrically supported with the second horizontal drive gear6364. The second vertical drive gear 6374 is rotatably supported on theproximal spine portion 6110 for travel therearound. The secondhorizontal drive gear 6364 is rotatably supported on a portion of saidsecond vertical drive gear 6374 for independent rotatable travelthereon. As can be seen in FIG. 140, the vertical driven gear 6192 is inmeshing engagement with the distal face portion 6375 of the secondvertical driven gear 6374.

In various forms, the first horizontal drive gear 6362 has a firstdiameter and the first vertical drive gear 6372 has a second diameter.As can be seen in FIGS. 139 and 140, the shaft 6361 is not on a commonaxis with shaft 6371. That is, the first horizontal driven gear 6362 andthe first vertical driven gear 6372 do not rotate about a common axis.Thus, when the shifter gear 6342 is positioned in a center “locking”position such that the shifter gear 6342 is in meshing engagement withboth the first horizontal driven gear 6362 and the first vertical drivegear 6372, the components of the articulation system 6140 are locked inposition. Thus, the shiftable shifter gear 6342 and the arrangement offirst horizontal and vertical drive gears 6362, 6372 as well as thearticulation shifter assembly 6320 collectively may be referred to as anarticulation locking system, generally designated as 6380.

In use, the robotic controller 1001 of the robotic system 1000 maycontrol the articulation system 6140 as follows. To articulate the endeffector 6012 to the left about the first tool articulation axisTA1-TA1, the robotic controller 1001 activates the shifter solenoidassembly 6350 to bring the shifter gear 6342 into meshing engagementwith the first horizontal drive gear 6362. Thereafter, the controller1001 causes a first rotary output motion to be applied to thearticulation drive gear 6322 to drive the shifter gear in a firstdirection to ultimately drive the horizontal driven gear 6182 in anotherfirst direction. The horizontal driven gear 6182 is driven to pivot thearticulation ring 6164 on the ball-shaped portion 6162 to thereby pullright upper cable 6144 and the right lower cable 6146 in the proximaldirection “PD”. To articulate the end effector 6012 to the right aboutthe first tool articulation axis TA1-TA1, the robotic controller 1001activates the shifter solenoid assembly 6350 to bring the shifter gear6342 into meshing engagement with the first horizontal drive gear 6362.Thereafter, the controller 1001 causes the first rotary output motion inan opposite direction to be applied to the articulation drive gear 6322to drive the shifter gear 6342 in a second direction to ultimately drivethe horizontal driven gear 6182 in another second direction. Suchactions result in the articulation control ring 6164 moving in such amanner as to pull the left upper cable 6150 and the left lower cable6152 in the proximal direction “PD”. In various embodiments the gearratios and frictional forces generated between the gears of the verticalgear assembly 6370 serve to prevent rotation of the vertical driven gear6192 as the horizontal gear assembly 6360 is actuated.

To articulate the end effector 6012 in the upper direction about thesecond tool articulation axis TA2-TA2, the robotic controller 1001activates the shifter solenoid assembly 6350 to bring the shifter gear6342 into meshing engagement with the first vertical drive gear 6372.Thereafter, the controller 1001 causes the first rotary output motion tobe applied to the articulation drive gear 6322 to drive the shifter gear6342 in a first direction to ultimately drive the vertical driven gear6192 in another first direction. The vertical driven gear 6192 is drivento pivot the articulation ring 6164 on the ball-shaped portion 6162 ofthe proximal spine portion 6110 to thereby pull right upper cable 6144and the left upper cable 6150 in the proximal direction “PD”. Toarticulate the end effector 6012 in the downward direction about thesecond tool articulation axis TA2-TA2, the robotic controller 1001activates the shifter solenoid assembly 6350 to bring the shifter gear6342 into meshing engagement with the first vertical drive gear 6372.Thereafter, the controller 1001 causes the first rotary output motion tobe applied in an opposite direction to the articulation drive gear 6322to drive the shifter gear 6342 in a second direction to ultimately drivethe vertical driven gear 6192 in another second direction. Such actionsthereby cause the articulation control ring 6164 to pull the right lowercable 6146 and the left lower cable 6152 in the proximal direction “PD”.In various embodiments, the gear ratios and frictional forces generatedbetween the gears of the horizontal gear assembly 6360 serve to preventrotation of the horizontal driven gear 6182 as the vertical gearassembly 6370 is actuated.

In various embodiments, a variety of sensors may communicate with therobotic controller 1001 to determine the articulated position of the endeffector 6012. Such sensors may interface with, for example, thearticulation joint 6100 or be located within the tool mounting portion6200. For example, sensors may be employed to detect the position of thearticulation control ring 6164 on the ball-shaped portion 6162 of theproximal spine portion 6110. Such feedback from the sensors to thecontroller 1001 permits the controller 1001 to adjust the amount ofrotation and the direction of the rotary output to the articulationdrive gear 6322. Further, as indicated above, when the shifter drivegear 6342 is centrally positioned in meshing engagement with the firsthorizontal drive gear 6362 and the first vertical drive gear 6372, theend effector 6012 is locked in the articulated position. Thus, after thedesired amount of articulation has been attained, the controller 1001may activate the shifter solenoid assembly 6350 to bring the shiftergear 6342 into meshing engagement with the first horizontal drive gear6362 and the first vertical drive gear 6372. In alternative embodiments,the shifter solenoid assembly 6350 may be spring activated to thecentral locked position.

In use, it may be desirable to rotate the surgical end effector 6012about the longitudinal tool axis LT-LT. In at least one embodiment, thetransmission arrangement 6204 on the tool mounting portion includes arotational transmission assembly 6400 that is configured to receive acorresponding rotary output motion from the tool drive assembly 1010 ofthe robotic system 1000 and convert that rotary output motion to arotary control motion for rotating the elongated shaft assembly 6008(and surgical end effector 6012) about the longitudinal tool axis LT-LT.In various embodiments, for example, a proximal end portion 6041 of theproximal closure tube 6040 is rotatably supported on the tool mountingplate 6202 of the tool mounting portion 6200 by a forward support cradle6205 and a closure sled 6510 that is also movably supported on the toolmounting plate 6202. In at least one form, the rotational transmissionassembly 6400 includes a tube gear segment 6402 that is formed on (orattached to) the proximal end 6041 of the proximal closure tube 6040 foroperable engagement by a rotational gear assembly 6410 that is operablysupported on the tool mounting plate 6202. As can be seen in FIG. 139,the rotational gear assembly 6410, in at least one embodiment, comprisesa rotation drive gear 6412 that is coupled to a corresponding second oneof the driven discs or elements 1304 on the adapter side 1307 of thetool mounting plate 6202 when the tool mounting portion 6200 is coupledto the tool drive assembly 1010. See FIG. 34. The rotational gearassembly 6410 further comprises a first rotary driven gear 6414 that isrotatably supported on the tool mounting plate 6202 in meshingengagement with the rotation drive gear 6412. The first rotary drivengear 6414 is attached to a drive shaft 6416 that is rotatably supportedon the tool mounting plate 6202. A second rotary driven gear 6418 isattached to the drive shaft 6416 and is in meshing engagement with tubegear segment 6402 on the proximal closure tube 6040. Application of asecond rotary output motion from the tool drive assembly 1010 of therobotic system 1000 to the corresponding driven element 1304 willthereby cause rotation of the rotation drive gear 6412. Rotation of therotation drive gear 6412 ultimately results in the rotation of theelongated shaft assembly 6008 (and the surgical end effector 6012) aboutthe longitudinal tool axis LT-LT. It will be appreciated that theapplication of a rotary output motion from the tool drive assembly 1010in one direction will result in the rotation of the elongated shaftassembly 6008 and surgical end effector 6012 about the longitudinal toolaxis LT-LT in a first direction and an application of the rotary outputmotion in an opposite direction will result in the rotation of theelongated shaft assembly 6008 and surgical end effector 6012 in a seconddirection that is opposite to the first direction.

In at least one embodiment, the closure of the anvil 2024 relative tothe staple cartridge 2034 is accomplished by axially moving a closureportion of the elongated shaft assembly 2008 in the distal direction“DD” on the spine assembly 2049. As indicated above, in variousembodiments, the proximal end portion 6041 of the proximal closure tube6040 is supported by the closure sled 6510 which comprises a portion ofa closure transmission, generally depicted as 6512. As can be seen inFIG. 139, the proximal end portion 6041 of the proximal closure tubeportion 6040 has a collar 6048 formed thereon. The closure sled 6510 iscoupled to the collar 6048 by a yoke 6514 that engages an annular groove6049 in the collar 6048. Such arrangement serves to enable the collar6048 to rotate about the longitudinal tool axis LT-LT while still beingcoupled to the closure transmission 6512. In various embodiments, theclosure sled 6510 has an upstanding portion 6516 that has a closure rackgear 6518 formed thereon. The closure rack gear 6518 is configured fordriving engagement with a closure gear assembly 6520. See FIG. 139.

In various forms, the closure gear assembly 6520 includes a closure spurgear 6522 that is coupled to a corresponding second one of the drivendiscs or elements 1304 on the adapter side 1307 of the tool mountingplate 6202. See FIG. 34. Thus, application of a third rotary outputmotion from the tool drive assembly 1010 of the robotic system 1000 tothe corresponding second driven element 1304 will cause rotation of theclosure spur gear 6522 when the tool mounting portion 6202 is coupled tothe tool drive assembly 1010. The closure gear assembly 6520 furtherincludes a closure reduction gear set 6524 that is supported in meshingengagement with the closure spur gear 6522 and the closure rack gear2106. Thus, application of a third rotary output motion from the tooldrive assembly 1010 of the robotic system 1000 to the correspondingsecond driven element 1304 will cause rotation of the closure spur gear6522 and the closure transmission 6512 and ultimately drive the closuresled 6510 and the proximal closure tube 6040 axially on the proximalspine portion 6110. The axial direction in which the proximal closuretube 6040 moves ultimately depends upon the direction in which the thirddriven element 1304 is rotated. For example, in response to one rotaryoutput motion received from the tool drive assembly 1010 of the roboticsystem 1000, the closure sled 6510 will be driven in the distaldirection “DD” and ultimately drive the proximal closure tube 6040 inthe distal direction “DD”. As the proximal closure tube 6040 is drivendistally, the distal closure tube 6042 is also driven distally by virtueof it connection with the proximal closure tube 6040. As the distalclosure tube 6042 is driven distally, the end of the closure tube 6042will engage a portion of the anvil 6024 and cause the anvil 6024 topivot to a closed position. Upon application of an “opening” out putmotion from the tool drive assembly 1010 of the robotic system 1000, theclosure sled 6510 and the proximal closure tube 6040 will be driven inthe proximal direction “PD” on the proximal spine portion 6110. As theproximal closure tube 6040 is driven in the proximal direction “PD”, thedistal closure tube 6042 will also be driven in the proximal direction“PD”. As the distal closure tube 6042 is driven in the proximaldirection “PD”, the opening 6045 therein interacts with the tab 6027 onthe anvil 6024 to facilitate the opening thereof. In variousembodiments, a spring (not shown) may be employed to bias the anvil 6024to the open position when the distal closure tube 6042 has been moved toits starting position. In various embodiments, the various gears of theclosure gear assembly 6520 are sized to generate the necessary closureforces needed to satisfactorily close the anvil 6024 onto the tissue tobe cut and stapled by the surgical end effector 6012. For example, thegears of the closure transmission 6520 may be sized to generateapproximately 70-120 pounds of closure forces.

In various embodiments, the cutting instrument is driven through thesurgical end effector 6012 by a knife bar 6530. See FIG. 139. In atleast one form, the knife bar 6530 is fabricated with a jointarrangement (not shown) and/or is fabricated from material that canaccommodate the articulation of the surgical end effector 6102 about thefirst and second tool articulation axes while remaining sufficientlyrigid so as to push the cutting instrument through tissue clamped in thesurgical end effector 6012. The knife bar 6530 extends through a hollowpassage 6532 in the proximal spine portion 6110.

In various embodiments, a proximal end 6534 of the knife bar 6530 isrotatably affixed to a knife rack gear 6540 such that the knife bar 6530is free to rotate relative to the knife rack gear 6540. The distal endof the knife bar 6530 is attached to the cutting instrument in thevarious manners described above. As can be seen in FIG. 139, the kniferack gear 6540 is slidably supported within a rack housing 6542 that isattached to the tool mounting plate 6202 such that the knife rack gear6540 is retained in meshing engagement with a knife drive transmissionportion 6550 of the transmission arrangement 6204. In variousembodiments, the knife drive transmission portion 6550 comprises a knifegear assembly 6560. More specifically and with reference to FIG. 139, inat least one embodiment, the knife gear assembly 6560 includes a knifespur gear 6562 that is coupled to a corresponding fourth one of thedriven discs or elements 1304 on the adapter side 1307 of the toolmounting plate 6202. See FIG. 34. Thus, application of another rotaryoutput motion from the robotic system 1000 through the tool driveassembly 1010 to the corresponding fourth driven element 1304 will causerotation of the knife spur gear 6562. The knife gear assembly 6560further includes a knife gear reduction set 6564 that includes a firstknife driven gear 6566 and a second knife drive gear 6568. The knifegear reduction set 6564 is rotatably mounted to the tool mounting plate6202 such that the first knife driven gear 6566 is in meshing engagementwith the knife spur gear 6562. Likewise, the second knife drive gear6568 is in meshing engagement with a third knife drive gear assembly6570. As shown in FIG. 139, the second knife driven gear 6568 is inmeshing engagement with a fourth knife driven gear 6572 of the thirdknife drive gear assembly 6570. The fourth knife driven gear 6572 is inmeshing engagement with a fifth knife driven gear assembly 6574 that isin meshing engagement with the knife rack gear 6540. In variousembodiments, the gears of the knife gear assembly 6560 are sized togenerate the forces needed to drive the cutting instrument through thetissue clamped in the surgical end effector 6012 and actuate the staplestherein. For example, the gears of the knife gear assembly 6560 may besized to generate approximately 40 to 100 pounds of driving force. Itwill be appreciated that the application of a rotary output motion fromthe tool drive assembly 1010 in one direction will result in the axialmovement of the cutting instrument in a distal direction and applicationof the rotary output motion in an opposite direction will result in theaxial travel of the cutting instrument in a proximal direction.

As can be appreciated from the foregoing description, the surgical tool6000 represents a vast improvement over prior robotic tool arrangements.The unique and novel transmission arrangement employed by the surgicaltool 6000 enables the tool to be operably coupled to a tool holderportion 1010 of a robotic system that only has four rotary outputbodies, yet obtain the rotary output motions therefrom to: (i)articulate the end effector about two different articulation axes thatare substantially transverse to each other as well as the longitudinaltool axis; (ii) rotate the end effector 6012 about the longitudinal toolaxis; (iii) close the anvil 6024 relative to the surgical staplecartridge 6034 to varying degrees to enable the end effector 6012 to beused to manipulate tissue and then clamp it into position for cuttingand stapling; and (iv) firing the cutting instrument to cut through thetissue clamped within the end effector 6012. The unique and novelshifter arrangements of various embodiments of the present inventiondescribed above enable two different articulation actions to be poweredfrom a single rotatable body portion of the robotic system.

The various embodiments of the present invention have been describedabove in connection with cutting-type surgical instruments. It should benoted, however, that in other embodiments, the inventive surgicalinstrument disclosed herein need not be a cutting-type surgicalinstrument, but rather could be used in any type of surgical instrumentincluding remote sensor transponders. For example, it could be anon-cutting endoscopic instrument, a grasper, a stapler, a clip applier,an access device, a drug/gene therapy delivery device, an energy deviceusing ultrasound, RF, laser, etc. In addition, the present invention maybe in laparoscopic instruments, for example. The present invention alsohas application in conventional endoscopic and open surgicalinstrumentation as well as robotic-assisted surgery.

FIG. 141 depicts use of various aspects of certain embodiments of thepresent invention in connection with a surgical tool 7000 that has anultrasonically powered end effector 7012. The end effector 7012 isoperably attached to a tool mounting portion 7100 by an elongated shaftassembly 7008. The tool mounting portion 7100 may be substantiallysimilar to the various tool mounting portions described hereinabove. Inone embodiment, the end effector 7012 includes an ultrasonically poweredjaw portion 7014 that is powered by alternating current or directcurrent in a known manner. Such ultrasonically-powered devices aredisclosed, for example, in U.S. Pat. No. 6,783,524, entitled ROBOTICSURGICAL TOOL WITH ULTRASOUND CAUTERIZING AND CUTTING INSTRUMENT, theentire disclosure of which is herein incorporated by reference. In theillustrated embodiment, a separate power cord 7020 is shown. It will beunderstood, however, that the power may be supplied thereto from therobotic controller 1001 through the tool mounting portion 7100. Thesurgical end effector 7012 further includes a movable jaw 7016 that maybe used to clamp tissue onto the ultrasonic jaw portion 7014. Themovable jaw portion 7016 may be selectively actuated by the roboticcontroller 1001 through the tool mounting portion 7100 in anyone of thevarious manners herein described.

FIG. 142 illustrates use of various aspects of certain embodiments ofthe present invention in connection with a surgical tool 8000 that hasan end effector 8012 that comprises a linear stapling device. The endeffector 8012 is operably attached to a tool mounting portion 8100 by anelongated shaft assembly 3700 of the type and construction describeabove. However, the end effector 8012 may be attached to the toolmounting portion 8100 by a variety of other elongated shaft assembliesdescribed herein. In one embodiment, the tool mounting portion 8100 maybe substantially similar to tool mounting portion 3750. However, variousother tool mounting portions and their respective transmissionarrangements describe in detail herein may also be employed. Such linearstapling head portions are also disclosed, for example, in U.S. Pat. No.7,673,781, entitled SURGICAL STAPLING DEVICE WITH STAPLE DRIVER THATSUPPORTS MULTIPLE WIRE DIAMETER STAPLES, the entire disclosure of whichis herein incorporated by reference.

Various sensor embodiments described in U.S. Patent ApplicationPublication No. 2011/0062212 to Shelton, I V et al., now U.S. Pat. No.8,167,185, the disclosure of which is herein incorporated by referencein its entirety, may be employed with many of the surgical toolembodiments disclosed herein. As was indicated above, the mastercontroller 1001 generally includes master controllers (generallyrepresented by 1003) which are grasped by the surgeon and manipulated inspace while the surgeon views the procedure via a stereo display 1002.See FIG. 25. The master controllers 1001 are manual input devices whichpreferably move with multiple degrees of freedom, and which oftenfurther have an actuatable handle for actuating the surgical tools. Someof the surgical tool embodiments disclosed herein employ a motor ormotors in their tool drive portion to supply various control motions tothe tool's end effector. Such embodiments may also obtain additionalcontrol motion(s) from the motor arrangement employed in the roboticsystem components. Other embodiments disclosed herein obtain all of thecontrol motions from motor arrangements within the robotic system.

Such motor powered arrangements may employ various sensor arrangementsthat are disclosed in the published U.S. patent application cited aboveto provide the surgeon with a variety of forms of feedback withoutdeparting from the spirit and scope of the present invention. Forexample, those master controller arrangements 1003 that employ amanually actuatable firing trigger can employ run motor sensor(s) toprovide the surgeon with feedback relating to the amount of forceapplied to or being experienced by the cutting member. The run motorsensor(s) may be configured for communication with the firing triggerportion to detect when the firing trigger portion has been actuated tocommence the cutting/stapling operation by the end effector. The runmotor sensor may be a proportional sensor such as, for example, arheostat or variable resistor. When the firing trigger is drawn in, thesensor detects the movement, and sends an electrical signal indicativeof the voltage (or power) to be supplied to the corresponding motor.When the sensor is a variable resistor or the like, the rotation of themotor may be generally proportional to the amount of movement of thefiring trigger. That is, if the operator only draws or closes the firingtrigger in a small amount, the rotation of the motor is relatively low.When the firing trigger is fully drawn in (or in the fully closedposition), the rotation of the motor is at its maximum. In other words,the harder the surgeon pulls on the firing trigger, the more voltage isapplied to the motor causing greater rates of rotation. Otherarrangements may provide the surgeon with a feed back meter 1005 thatmay be viewed through the display 1002 and provide the surgeon with avisual indication of the amount of force being applied to the cuttinginstrument or dynamic clamping member. Other sensor arrangements may beemployed to provide the master controller 1001 with an indication as towhether a staple cartridge has been loaded into the end effector,whether the anvil has been moved to a closed position prior to firing,etc.

In alternative embodiments, a motor-controlled interface may be employedin connection with the controller 1001 that limit the maximum triggerpull based on the amount of loading (e.g., clamping force, cuttingforce, etc.) experienced by the surgical end effector. For example, theharder it is to drive the cutting instrument through the tissue clampedwithin the end effector, the harder it would be to pull/actuate theactivation trigger. In still other embodiments, the trigger on thecontroller 1001 is arranged such that the trigger pull location isproportionate to the end effector-location/condition. For example, thetrigger is only fully depressed when the end effector is fully fired.

In still other embodiments, the various robotic systems and toolsdisclosed herein may employ many of the sensor/transponder arrangementsdisclosed above. Such sensor arrangements may include, but are notlimited to, run motor sensors, reverse motor sensors, stop motorsensors, end-of-stroke sensors, beginning-of-stroke sensors, cartridgelockout sensors, sensor transponders, charge accumulating devices,switching circuits, removable battery packs, etc. The sensors may beemployed in connection with any of the surgical tools disclosed hereinthat are adapted for use with a robotic system. The sensors may beconfigured to communicate with the robotic system controller. In otherembodiments, components of the shaft/end effector may serve as antennasto communicate between the sensors and the robotic controller. In stillother embodiments, the various remote programming device arrangementsdescribed above may also be employed with the robotic controller.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, the device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, the devicecan be disassembled, and any number of the particular pieces or parts ofthe device can be selectively replaced or removed in any combination.Upon cleaning and/or replacement of particular parts, the device can bereassembled for subsequent use either at a reconditioning facility, orby a surgical team immediately prior to a surgical procedure. Thoseskilled in the art will appreciate that reconditioning of a device canutilize a variety of techniques for disassembly, cleaning/replacement,and reassembly. Use of such techniques, and the resulting reconditioneddevice, are all within the scope of the present application.

Although the present invention has been described herein in connectionwith certain disclosed embodiments, many modifications and variations tothose embodiments may be implemented. For example, different types ofend effectors may be employed. Also, where materials are disclosed forcertain components, other materials may be used. The foregoingdescription and following claims are intended to cover all suchmodification and variations.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdoes not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

What is claimed is:
 1. A surgical tool for use with a robotic systemthat has a tool drive assembly that is operatively coupled to a controlunit of the robotic system that is operable by inputs from an operator,said surgical tool comprising: an end effector comprising a first jawand a second jaw, wherein the first jaw is rotatable relative to thesecond jaw; a powered closure actuator coupled to a rotary actuationmember located proximal to the end effector, wherein the powered closureactuator is actuatable to close the first jaw during a closed stroke ata first rate during a first portion of the closure stroke and a secondrate during a second portion of the closure stroke; an unspent staplecartridge including staples removably stored therein, wherein theunspent staple cartridge comprises a sled movable from a proximal end ofthe unspent staple cartridge toward a distal end of the unspent staplecartridge, and wherein the unspent staple cartridge is seatable in theend effector; an elongate shaft; an I-beam configured to couple thefirst jaw to the second jaw and deploy the staples from the staplecartridge, wherein the I-beam comprises: a first cam for interfacingwith the first jaw; a second cam for interfacing with the second jaw; adistal solid portion connecting the first cam and the second cam; and aflexible proximal portion; a rotatable actuator in operable engagementwith the I-beam, wherein an initial rotation of the rotatable actuatordrives the I-beam from a first position into an intermediate position ata first rate, wherein a subsequent rotation of the rotatable actuatordrives the I-beam from the intermediate position to a second position ata second rate, and wherein the first rate is greater than the secondrate; and a locking system which prevents the advancement of the I-beamto the second position by blocking the distal solid portion if theunspent staple cartridge is not correctly seated in said end effector.2. A surgical instrument for use with a robotic surgical system, whereinthe robotic surgical system comprises a tool drive assembly that isoperatively coupled to a control unit of the robotic surgical systemthat is operable by inputs from an operator, the surgical instrumentcomprising: an end effector comprising a first jaw and a second jaw,wherein the first jaw is rotatable relative to the second jaw; a poweredclosure actuator coupled to a rotary actuation member located proximalto the end effector, wherein the powered closure actuator is actuatableto close the first jaw during a closure stroke at a first rate during afirst portion of the closure stroke and a second rate during a secondportion of the closure stroke; an unspent staple cartridge includingstaples removably stored therein, wherein the unspent staple cartridgecomprises a sled movable from a proximal end of the unspent staplecartridge toward a distal end of the unspent staple cartridge, andwherein the unspent staple cartridge is seatable in the end effector; anelongate shaft; an I-member configured to couple the first jaw to thesecond jaw and deploy the staples from the staple cartridge, wherein theI-member comprises: a first cam configured to interface with the firstjaw; a second cam configured to interface with the second jaw; a distalsolid portion connecting the first cam and the second cam; and aflexible proximal portion; a rotatable actuator in operable engagementwith the I-member, wherein an initial rotation of the rotatable actuatordrives the I-member from a first position into an intermediate positionat a first rate, wherein a subsequent rotation of the rotatable actuatordrives the I-member from the intermediate position to a second positionat a second rate, and wherein the first rate is greater than the secondrate; and a locking system which prevents the advancement of theI-member to the second position by blocking the distal solid portion ifthe unspent staple cartridge is not properly seated in the end effector.